520-TD001E-EN-E PowerFlex 520-Series AC Drive

Technical Data

PowerFlex 520-Series AC Drive Specifications Original Instructions

Topic

Page

Product Overview

2

Catalog Number Explanation

8

Technical Specifications

9

Environmental Specifications

12

Certifications

13

Dimensions and Weights

14

Design Considerations

16

Fuses and Circuit Breaker Ratings

27

Accessories and Dimensions

32

Safe-Torque-Off Function

42

Additional Resources

47

Drive Features: AppView™, CustomView™, QuickView™, and MainsFree™ configuration and programming tools.

PowerFlex 520-Series AC Drive Specifications

Product Overview The PowerFlex® 520-Series AC drive delivers an innovative design that is remarkably versatile and can accommodate systems ranging from standalone machines to simple system integration. The PowerFlex 523 drive provides general purpose control for applications ranging up to 30 HP and 22 kW. The PowerFlex 525 drive provides maximum flexibility and performance ranging up to 30 HP and 22 kW. By combining a variety of motor control options, communications, energy savings and standard safety features in a costeffective drive, the PowerFlex 520-Series drive is suitable for a wide array of applications. Maximize your system performance and productivity by taking advantage of the following key features offered in a PowerFlex 520-Series drive.

PowerFlex 520-Series AC Drives Feature Modular Design • Detachable control module and power module allow simultaneous configuration and installation. • Each drive has a standard control module used across the entire power range. • MainsFree™ configuration allows you to simply connect your control module to a PC with a standard USB cable and quickly upload, download, and flash the drive with new settings. • Support for accessory cards without affecting footprint. (PowerFlex 523 drives support one, PowerFlex 525 drives support two)

Packaging and Mounting • Installation can be quick and easy using the DIN rail mounting feature on A, B, and C frame drives. Panel mounting is also available, providing added flexibility. • Zero Stacking™ is allowed for ambient temperatures up to 45 °C, saving valuable panel space. • Integral filtering is available on all 200V and 400V ratings, providing a cost-effective means of meeting EN61800-3 Category C2 and C3 EMC requirements. External filters provide compliance to EN61800-3 Category C1, C2, and C3 EMC requirements for all PowerFlex 520-Series ratings. • An optional IP 30, NEMA/UL Type 1 conduit box is easily adapted to the standard IP 20 (NEMA Type Open) product, providing increased environmental ratings.

Optimized Performance • Removable MOV to ground provides trouble-free operation when used on ungrounded distribution systems. • A relay pre-charge limits inrush current. • Integral brake transistor, available on all ratings, provides dynamic braking capability with simple low cost brake resistors. • A jumper to switch between 24V DC sink or source control for control wiring flexibility. • Dual Overload Rating available for drives above 15 HP/11 kW. Normal duty: 110% overload for 60 seconds or 150% for 3 seconds. Heavy duty: 150% overload for 60 seconds or 180% overload (200% programmable) for 3 seconds provides robust overload protection. • Adjustable PWM frequency up to 16 kHz ensures quiet operation.

2

Rockwell Automation Publication 520-TD001E-EN-E - July 2016


PowerFlex 520-Series AC Drive Advanced Features Control Performance • Variety of motor control options, including: • Volts per hertz (V/Hz) • Sensorless Vector Control (SVC) • Closed loop velocity vector control (PowerFlex 525 drives only) • Permanent Magnet motor control (PowerFlex 525 drives only) • Variety of Positioning Control, including: • PointStop™ stops motor load in a consistent position without encoder feedback • Closed loop feedback with an optional encoder card (PowerFlex 525 drives only) • Point-to-point positioning mode (PowerFlex 525 drives only) • Integral PID functionality enhances application flexibility (PowerFlex 523 drives have one PID loop, PowerFlex 525 drives have two PID loops)

I/O Wiring PowerFlex 523 • One (1) Analog Input (unipolar voltage or current) independently isolated from the rest of the drive I/O. • Five (5) Digital Inputs (four programmable) provide application versatility.

PowerFlex 523 Series B Control I/O Wiring Block Diagram

01 02 03 SNK

SRC

04 05 06

Relay N.O. Relay Common Relay N.C.

R2

+24V

R3

+10V

11 12 13

4-20 mA

14 0-10V

• One (1) Analog Output(1) which is jumper selectable between either 0-10V or 0-20 mA. This scalable, 10-bit output is suitable for metering or as a speed reference to another device. • One (1) Relay Output (form C) can be used to indicate various drive, motor or logic conditions.

0/4-20 mA

C1

J13

R1

Safety 1 Safety 2 Safety +24V

Digital In

Analog In

Analog Out 0-10V

SRC

0-10V

R2

01

02

12

11

03

13

J7 Pulse In

04

14

05

15

C1

Safe-Torque-Off

02

S2

03

S+ SRC

04

08 +24V 11 R1

+10V

12

R2

13 R5

14

R6

15

0-10V

16

0/4-20 mA

17 18

30V DC 50 mA Non-inductive

+10V DC Analog Input

R2

R5

S2

Comm Common

19

(1) Stop DigIn TermBlk 02/(2) Start/Run FWD DigIn TermBlk 03/ Direction/Run REV Digital Common DigIn TermBlk 05 DigIn TermBlk 06 DigIn TermBlk 07/Pulse DigIn TermBlk 08 +24V DC +10V DC 0-10V (or ±10V) Input Analog Common

Pot must be 1...10 k ohm 2 W min.

4-20mA Input Analog Output Opto Output 1

24V (3) Common

Opto Output 2 Opto Common RJ45 Shield Comm Common

SRC 01

11

Typical SNK wiring

J5 SNK

Digital Input

R6

S+

Typical SRC wiring

Digital In

DigIn TermBlk 07 Sel

0-10V R1

J9 Pulse In

14

(4) Pot must be 4-20 mA 1...10 k ohm source 2 W min.

RJ45 Shield

C1 J10 0/4-20mA

13

Analog Common (3) Analog Output

C2

S1


+24V DC

C2

07

Relay 2 N.C.

DigIn TermBlk 06

06

06

Relay 2 Common

DigIn TermBlk 05/Pulse

81

05

Relay 1 N.O.

Digital Common

Digital Input

SNK

Relay 1 Common

Typical SNK wiring

RS485 (DSI)

01 S1

Analog Out

• Two (2) Analog Inputs (one unipolar and one bipolar) are independently isolated from the rest of the drive I/O. These inputs can be toggled via a digital input. • Seven (7) Digital Inputs (six programmable) provide application versatility. • One (1) Analog Output which is jumper selectable between either 0-10V or 0-20 mA. This scalable, 10-bit output is suitable for metering or as a speed reference to another drive. • Two (2) Opto Outputs and two (2) Relay Outputs (one form A and one form B) can be used to indicate various drive, motor or logic conditions.

J8 SNK

DigIn TermBlk 05 Sel

J4

4-20 mA 0/4-20 mA

R3

PowerFlex 525

15

C2

PowerFlex 525 Control I/O Wiring Block Diagram

Typical SRC wiring

R1

0-10V

(1) Analog output (terminal 15) is only available on PowerFlex 523 series B drive and requires firmware 3.001 and later to configure the analog output parameters.

(1) Stop DigIn TermBlk 02/(2) Start/Run FWD DigIn TermBlk 03/ Direction/Run REV

12

02

13

03

14

04

15

05

16

06

17

07

18

08

C1

C2

19

3


Communications • Embedded EtherNet/IP™ port allows easy configuration, control, and collection of drive data over the network. (PowerFlex 525 drives only) • Dual port EtherNet/IP option card supports Device Level Ring (DLR) topologies, providing fault-tolerant connectivity for optimum drive availability. • Integral RS485/DSI communications enable the drives to be used in a multi-drop network configuration. • Optional communication cards such as DeviceNet™, and PROFIBUS DP™ can improve machine performance. • Online EDS file creation with RSNetWorx™ providing ease of set-up on a network.

Optimized for Common DC Bus Installations Enhanced Control of Internal Pre-charge Common DC Bus offers additional inherent breaking capabilities by utilizing all the drives/loads on the bus for energy absorption offering higher efficiency and cost savings. The PowerFlex 520-Series drive has been optimized for use in Common DC Bus or Shared DC Bus installations. • Configurable pre-charge control using digital inputs. • Direct DC Bus connection to power terminal blocks.

Improved Ride Through Operation Down to 1/2 Line Voltage The PowerFlex 520-Series drive allows for the selection of 1/2 DC Bus operation, for use in critical applications where continued drive output is desired even in the event of brown out or low voltage conditions. The PowerFlex 520-Series drive also supports enhanced inertia ride through for additional low voltage mitigation. • Selectable 1/2 line voltage operation. • Increased power loss ride through.

4



Additional Features of PowerFlex 525 Drives Closed Loop Feedback Encoder/Pulse Train Input The PowerFlex 525 drive allows for configurable closed loop control with an optional encoder card for either speed or position feedback for improved speed regulation, basic position control, or other pulse inputs for motor control. • Improved speed regulation • Basic position control

Basic Position Control Local Position Control • Position regulator with StepLogic™ • 8 positions (local logic) Outer Position Control Loop • Analog input bipolar mode offers improved zero-cross performance. • Simple motion control applications with more complex position profiles. • Speed reference supplied to drive via Analog Input or multiple field bus network options. • Speed ratio available for simple draw applications.

Feedback Details

Pulse Train Input • Configurable Input Voltage 5V/12V/24V DC autodetect • Input Frequency up to 100 kHz

Encoder Signal – Single-Ended, Dual Channel

to Power Supply Common +V Cm BB AA

B NOT B A NOT A

I/O

Connection Example

Encoder Power – External Power Source Encoder Signal – Differential, Dual Channel

Common

to SHLD External Power Supply

+

Line Driver Type Incremental Encoder Option Card Encoder Wiring Examples I/O Connection Example • Quadrature (dual channel) or Single Channel +12V DC Encoder • 5V/12V DC supply, 10 mA min per channel (250 mA) +V Power – Cm Common Internal Drive B• Single Ended or Differential (A, B Channel) B Power to SHLD AInternal (drive) A • Duty Cycle of 50%, +10% 12V DC, 250 mA • Input Frequency up to 250 kHz

+V Cm BB AA

to SHLD B NOT B A NOT A

to SHLD

Safety Inside using Safe-Torque-Off Function Safe Torque-Off is a standard safety feature of the PowerFlex 525 drive to help protect personnel and equipment. Safe Torque-off allows you to restart your application faster after a safety-related situation. • Safe Torque-Off functionality removes rotational power without powering down the drive. • Embedded safety reduces wiring and saves on installation space. • Meets ISO 13849-1 standards and provides safety ratings up to and including SIL 2/PLd.


5


Communications and Software Versatile Programming and Network Solutions • PowerFlex 520-Series drives are compatible with any device that acts as a RTU Master and supports standard 03 and 06 RTU commands. • A network can be configured using PowerFlex 520-Series drives for high performance and flexible configuration capabilities. • Embedded port for EtherNet/IP (PowerFlex 525 drives only) • EtherNet/IP dual-port option card • DeviceNet option card • PROFIBUS DP option card • A multi-drive solution can be reached using a single PowerFlex 520-Series drive, with the ability for up to five (5) drives to reside on one (1) node. • Integral RS485 communications enable the drives to be used in a multi-drop network configuration. A serial converter module (SCM) provides connectivity to any controller with a DF1 port. The SCM can be eliminated if the controller acts as a RTU Master.

RTU up to 31 PowerFlex 520-Series, PowerFlex 4, or PowerFlex 40 drives Network Communication Node 1

PowerFlex 520-Series with Comms card

Node 2


Node 3


DeviceNet to EtherNet/IP

RTU up to 4 PowerFlex 520-Series, PowerFlex 4, or PowerFlex 40 drives

DF1 SCM

RTU up to 31 PowerFlex 520-Series, PowerFlex 4, or PowerFlex 40 drives

PC Programming Software Connected Components Workbench™ • Supports plug-and-play connectivity through a standard USB connection. • AppView™ tool provides parameter groups for several of the most common applications. • Create and save custom parameter groups using the CustomView™ tool. • Supports PowerFlex drives, Micro800™ controllers and PanelView™ component graphic terminals. Studio 5000™ Logix Designer • Add-on profiles (AOPs) for PowerFlex 520-seriers AC drives provide seamless integration into the Logix environment. • Configuration files from Studio 5000 Logix Designer(1) can be transferred directly to the PowerFlex 520-Series drive over EtherNet/IP. • Automatic Device Configuration (ADC) uploads configuration parameters to a replaced drive, minimizing the need for a manual reconfiguration. (1) The Logix Designer application is the rebranding of RSLogix 5000 software. You can also use RSLogix 5000 version 17 or greater.

6



PowerFlex 523 Drive Family

Frame A

Frame B

Frame C

Frame D

Frame E

PowerFlex 525 Drive Family

Frame A

Frame B

Frame C

Frame D


Frame E

7


Catalog Number Explanation 1-3

4

5

6-8

9

10

11

12

13

14

25B

–

B

2P3

N

1

1

4

–

–

Drive

Dash

Voltage Rating

Rating

Enclosure

Reserved

Emission Class

Reserved

Dash

Dash

Code 25A 25B

Type PowerFlex 523 PowerFlex 525 Code V A B D E

Code 0 1 Voltage 120V AC 240V AC 240V AC 480V AC 600V AC

Phase 1 1 3 3 3

Code 1 Code N

EMC Filter No Filter Filter

Braking Standard

Interface Module Standard

Enclosure IP20 NEMA / Open

Output Current @ 1 Phase, 100...120V Input Code Amps Frame ND HD HP kW HP 1.6 A 0.25 0.2 0.25 1P6(1) 2P5 2.5 A 0.5 0.4 0.5 4P8 4.8 B 1.0 0.75 1.0 6P0 6.0 B 1.5 1.1 1.5

kW 0.2 0.4 0.75 1.1

Output Current @ 1 Phase, 200...240V Input Code Amps Frame ND HD HP kW HP 1P6(1) 1.6 A 0.25 0.2 0.25 2P5 2.5 A 0.5 0.4 0.5 4P8 4.8 A 1.0 0.75 1.0 8P0 8.0 B 2.0 1.5 2.0 011 11.0 B 3.0 2.2 3.0

kW 0.2 0.4 0.75 1.5 2.2

Output Current @ 3Phase, 200...240V Input Code Amps Frame ND HD HP kW HP 1.6 A 0.25 0.2 0.25 1P6(1) 2P5 2.5 A 0.5 0.4 0.5 5P0 5.0 A 1.0 0.75 1.0 8P0 8.0 A 2.0 1.5 2.0 011 11.0 A 3.0 2.2 3.0 017 17.5 B 5.0 4.0 5.0 024 24.0 C 7.5 5.5 7.5 032 32.2 D 10.0 7.5 10.0 048(2) 48.3 E 15.0 11.0 10.0 062(2) 62.1 E 20.0 15.0 15.0

kW 0.2 0.4 0.75 1.5 2.2 4.0 5.5 7.5 7.5 11.0

Output Current @ 3 Phase, 380...480V Input Code Amps Fram ND HD e HP kW HP 1P4 1.4 A 0.5 0.4 0.5 2P3 2.3 A 1.0 0.75 1.0 4P0 4.0 A 2.0 1.5 2.0 6P0 6.0 A 3.0 2.2 3.0 010 10.5 B 5.0 4.0 5.0 013 13.0 C 7.5 5.5 7.5 017 17.0 C 10.0 7.5 10.0 024 24.0 D 15.0 11.0 15.0 030(2) 30.0 D 20.0 15.0 15.0 (2) 037 37.0 E 25.0 18.5 20.0 043(2) 43.0 E 30.0 22.0 25.0

kW 0.4 0.75 1.5 2.2 4.0 5.5 7.5 11.0 11.0 15.0 18.5

Output Current @ 3 Phase, 525...600V Input Code Amps Fram ND HD e HP kW HP 0P9 0.9 A 0.5 0.4 0.5 1P7 1.7 A 1.0 0.75 1.0 3P0 3.0 A 2.0 1.5 2.0 4P2 4.2 A 3.0 2.2 3.0 6P6 6.6 B 5.0 4.0 5.0 9P9 9.9 C 7.5 5.5 7.5 012 12.0 C 10.0 7.5 10.0 019 19.0 D 15.0 11.0 15.0 022(2) 22.0 D 20.0 15.0 15.0 (2) 027 27.0 E 25.0 18.5 20.0 032(2) 32.0 E 30.0 22.0 25.0

kW 0.4 0.75 1.5 2.2 4.0 5.5 7.5 11.0 11.0 15.0 18.5

(1) This rating is only available for PowerFlex 523 drives. (2) Normal and Heavy Duty ratings are available for this drive.

8

Code 4



Technical Specifications Protection Specifications

PowerFlex 523

Bus Overvoltage Trip 100...120V AC Input: 200...240V AC Input: 380...480V AC Input: 525...600V AC Input:

405V DC bus (equivalent to 150V AC incoming line) 405V DC bus (equivalent to 290V AC incoming line) 810V DC bus (equivalent to 575V AC incoming line) 1005V DC bus (equivalent to 711V AC incoming line)

Bus Undervoltage Trip 100...120V AC Input: 200...240V AC Input: 380...480V AC Input: 525...600V AC Input P038 = 3 “600V”: P038 = 2 “480V”:

PowerFlex 525

190V DC bus (equivalent to 75V AC incoming line) 190V DC bus (equivalent to 150V AC incoming line) 390V DC bus (equivalent to 275V AC incoming line) 487V DC bus (equivalent to 344V AC incoming line) 390V DC bus (equivalent to 275V AC incoming line)

Power Ride-Thru:

100 ms

Logic Control Ride-Thru:

0.5 s minimum, 2 s typical

Electronic Motor Overload Protection:

Provides class 10 motor overload protection according to NEC article 430 and motor over-temperature protection according to NEC article 430.126 (A) (2). UL 508C File 29572.

Overcurrent:

200% hardware limit, 300% instantaneous fault

Ground Fault Trip:

Phase-to-ground on drive output

Short Circuit Trip:

Phase-to-phase on drive output

Electrical Specifications

PowerFlex 523

Voltage Tolerance:

-15% / +10%

Frequency Tolerance:

47...63 Hz

Input Phases:

Three-phase input provides full rating. Single-phase input provides 35% rating on three-phase drives.

Displacement Power Factor:

0.98 across entire speed range

Maximum Short Circuit Rating:

100,000 Amps Symmetrical

Actual Short Circuit Rating:

Determined by AIC Rating of installed fuse/circuit breaker

Transistor Type:

Isolated Gate Bipolar Transistor (IGBT)

Internal DC Bus Choke 200...240V AC Input: 380...480V AC Input: 525...600V AC Input:

Only for Frame E drive ratings 11 kW (15 HP) 15...18.5 kW (20...25 HP) – Heavy Duty 15...18.5 kW (20...25 HP) – Heavy Duty

PowerFlex 525

Control Specifications

PowerFlex 523

Method

Sinusoidal PWM, Volts/Hertz, Sensorless Vector Control, Economizer SVC motor control, Closed Loop Velocity Vector Control, Surface Mount and Interior Permanent Magnet Motor (without encoder), Interior Permanent Magnet Motor (with encoder) (Closed Loop Velocity Vector Control and PM motor control are not applicable to PowerFlex 523 drives)

PowerFlex 525

Carrier Frequency

2...16 kHz, Drive rating based on 4 kHz

Frequency Accuracy Digital Input: Analog Input: Analog Output:

Within ±0.05% of set output frequency Within 0.5% of maximum output frequency, 10-Bit resolution ±2% of full scale, 10-Bit resolution


9


Specifications

PowerFlex 523

Performance V/Hz (Volts per Hertz): SVC (Sensorless Vector): SVC Economizer:

±1% of base speed across a 60:1 speed range ±0.5% of base speed across a 100:1 speed range ±0.5% of base speed across a 100:1 speed range

VVC (Velocity Vector Control): PM Motor(1): Performance with Encoder SVC (Sensorless Vector): SVC Economizer: VVC (Velocity Vector Control): PM Motor (iPM motor, 10 HP rating and below)(1):

PowerFlex 525

(Applicable to PowerFlex 525 drives only) ±0.5% of base speed across a 60:1 speed range ±0.5% of base speed, up to a 20:1 speed range (Applicable to PowerFlex 525 drives only) ±0.1% of base speed across a 100:1 speed range(2) ±0.1% of base speed across a 100:1 speed range(2) ±0.1% of base speed across a 1000:1 speed range(2) ±0.1% of base speed, up to a 60:1 speed range

Output Voltage Range:

0V to rated motor voltage

Output Frequency Range:

0...500 Hz (programmable)

Efficiency:

97.5% (typical)

Stop Modes:

Multiple programmable stop modes including – Ramp, Coast, DC-Brake, and Ramp-to-Stop

Accel/Decel:

Four independently programmable accel and decel times. Each time may be programmed from 0...600 s in 0.01 s increments.

Intermittent Overload Normal Duty: Heavy Duty:

110% Overload capability for up to 60 s, 150% for up to 3 s Applies for power rating above 15 kW (20 HP) only. Based on 480V drive rating. 150% Overload capability for up to 60 s, 180% for up to 3 s (200% programmable)

(1) For details on specific motor performance, see Knowledge Base article “PowerFlex 525 PM Motor Performance Testing Summary”. (2) For more information, see the PowerFlex 520-Series Adjustable Frequency AC Drive User Manual, publication 520-UM001.

Control Inputs Specifications

PowerFlex 523

Digital

Analog

10

Bandwidth:

10 Rad/s for open and closed loop

Quantity:

(1) Dedicated for stop (4) Programmable

Current:

6 mA

Type Source Mode (SRC): Sink Mode (SNK):

18...24V = ON, 0...6V = OFF 0...6V = ON, 18...24V = OFF

Pulse Train Quantity: Input Signal: Input Frequency: Current Consumption:

(1) Shared with one of the programmable digital input terminals. Transistor contact (open collector) 0...100 kHz 7 mA @ 24V DC maximum

Quantity:

(1) Isolated, 0-10V and 4-20 mA

Specification Resolution: 0-10V DC Analog: 4-20 mA Analog: External Pot:

10-bit 100k ohm input impedance 250 ohm input impedance 1...10k ohm, 2 W minimum

PowerFlex 525 (1) Dedicated for stop (6) Programmable

(2) Isolated, -10-10V and 4-20 mA



Control Outputs Specifications

PowerFlex 523

PowerFlex 525

Relay

Quantity:

(1) Programmable Form C

(2) 1 Programmable Form A and 1 Programmable Form B

Specification Resistive Rating: Inductive Rating:

3.0 A @ 30V DC, 3.0 A @ 125V, 3.0 A @ 240V AC 0.5 A @ 30V DC, 0.5 A @ 125V, 0.5 A @ 240V AC

Quantity:

–

Opto

(2) Programmable

Specification: Analog

30V DC, 50 mA Non-inductive

Quantity:

(1) Non-Isolated 0-10V or 4-20 mA(1)

Specification Resolution: 0-10V DC Analog: 4-20 mA Analog:

10-bit 1 k ohm minimum 525 ohm maximum

(1) Feature is not applicable to PowerFlex 523 series A drives.

Encoder Specifications

PowerFlex 523

Type:

–

PowerFlex 525 Incremental, dual channel

Supply:

12V, 250 mA

Quadrature:

90°, ±27° @ 25 °C

Duty Cycle:

50%, +10%

Requirements:

Encoders must be line driver type, quadrature (dual channel) or pulse (single channel), 3.5...26V DC output, single-ended or differential and capable of supplying a minimum of 10 mA per channel. Allowable input is DC up to a maximum frequency of 250 kHz. The encoder I/O automatically scales to allow 5V, 12V and 24V DC nominal voltages.


11


Environmental Specifications Specifications Altitude Without derating: With derating: Surrounding Air Temperature, max. Without derating: With derating: Storage Temperature Frame A...D: Frame E: Atmosphere:

PowerFlex 523 PowerFlex 525 See Current Derating Curves on page 18 for derating guidelines. 1000 m (3300 ft) max. Up to 4000 m (13,200 ft) max., with the exception of 600V drives at 2000 m (6600 ft) max. See Current Derating Curves on page 18 for derating guidelines. -20...50 °C (-4...122 °F) -20...60 °C (-4...140 °F) or -20...70 °C (-4...158 °F) with optional Control Module Fan kit. -40...85 °C (-40...185 °F) -40...70 °C (-40...158 °F)

IMPORTANT

Relative Humidity: Shock: Vibration:

0...95% noncondensing Complies with IEC 60068-2-27 Complies with IEC 60068-2-6:1995 Frame Size A B C D E

Conformal Coating: Surrounding Environment Pollution Degree Pollution Degree 1 & 2: Sound Pressure Level (A-weighted) Frame A & B: Frame C: Frame D: Frame E:

12

Drive must not be installed in an area where the ambient atmosphere contains volatile or corrosive gas, vapors or dust. If the drive is not going to be installed for a period of time, it must be stored in an area where it will not be exposed to a corrosive atmosphere.

Operating and Nonoperating Force (Shock/Vibration) 15 g / 2 g 15 g / 2 g 15 g / 2 g 15 g / 2 g 15 g / 1.5 g

Mounting Type DIN rail or screw DIN rail or screw DIN rail or screw Screw only Screw only

Nonoperating (Transportation) Force (Shock/Vibration) Mounting Type 30 g/ 2.5 g Screw only 30 g/ 2.5 g Screw only 30 g/ 2.5 g Screw only 30 g/ 2.5 g Screw only 30 g/ 2.5 g Screw only

Complies with: IEC 60721-3-3 to level 3C2 (chemical and gases only) All enclosures acceptable. Measurements are taken 1 m from the drive. Maximum 53 dBA Maximum 57 dBA Maximum 64 dBA Maximum 68 dBA



Certifications Certification c-UL-us

PowerFlex 523 Listed to UL508C and CAN/CSA-C22.2 No. 14-05.

RCM

Australian Communications and Media Authority In conformity with the following: Radiocommunications Act: 1992 Radiocommunications Standard: 2008 Radiocommunications Labelling Notice: 2008 Standards applied: EN 61800-3 In conformity with the following European Directives: 2014/35/EU Low Voltage Directive (LVD) 2014/30/EU EMC Directive (EMC) 2014/34/EU ATEX Directive (ATEX) 2006/42/EC Machinery Directive (MD) Standards applied: EN 61800-3 EN 61800-5-1 (Applicable to PowerFlex 525 drives only) TÜV Rheinland Standards applied: EN ISO 13849-1 EN 61800-5-2 EN 61508 PARTS 1-7 EN 62061 EN 60204-1 Certified to ISO 13849-1 SIL2/PLd with embedded Safe-Torque-Off function Meets Functional Safety (FS) when used with embedded Safe-Torque-Off function (Applicable to PowerFlex 525 drives only) Certified to ATEX directive 2014/34/EU Group II Category (2) GD Applications with ATEX Approved Motors

CE

TUV Functional Safety Type Approved www.tuv.com ID 0600000000

ATEX II (2) G D

PowerFlex 525

TUV 12 ATEX 7199 X KCC

Korean Registration of Broadcasting and Communications Equipment Compliant with the following standards: Article 58-2 of Radio Waves Act, Clause 3 EAC Standards applied: Low Voltage TP TC 004/2011 EMC TP TC 020/2011 AC 156 Tested by Trentec to be compliant with AC156 Acceptance Criteria for Seismic Qualification Testing of Nonstructural Components and 2003 International Building Code for worst-case seismic level for USA excluding site class F SEMI F47 Electric Power Research Institute Certified compliant with the following standards: SEMI F47 IEC 61000-4-11 IEC 61000-4-34 Lloyds Register (Applicable to PowerFlex 525 drives only) Lloyd’s Register Type Approval Certificate 12/10068(E1) RoHS Compliant with the European “Restriction of Hazardous Substances” Directive The drive is also designed to meet the appropriate portions of the following specifications: NFPA 70 - US National Electrical Code NEMA ICS 7.1 - Safety standards for Construction and Guide for Selection, Installation and Operation of Adjustable Speed Drive Systems.


13


Dimensions and Weights Frame/Rating Cross-Reference Catalog Number Description

25B Drive

-

V

2P5

N

1

0

4

Voltage Rating

Rating

Enclosure

HIM

Emission Class

Version

PowerFlex 520-Series Drive Ratings Output Ratings Normal Duty Heavy Duty PowerFlex 523 PowerFlex 525 Output Catalog No. Catalog No. HP kW HP kW Current (A) 100...120V AC (-15%, +10%) – 1-Phase Input, 0...230V 3-Phase Output 25A-V1P6N104 – 0.25 0.2 0.25 0.2 1.6 25A-V2P5N104 25B-V2P5N104 0.5 0.4 0.5 0.4 2.5 25A-V4P8N104 25B-V4P8N104 1.0 0.75 1.0 0.75 4.8 25A-V6P0N104 25B-V6P0N104 1.5 1.1 1.5 1.1 6.0 200...240V AC (-15%, +10%) – 1-Phase Input, 0...230V 3-Phase Output 25A-A1P6N104 – 0.25 0.2 0.25 0.2 1.6 25A-A2P5N104 25B-A2P5N104 0.5 0.4 0.5 0.4 2.5 25A-A4P8N104 25B-A4P8N104 1.0 0.75 1.0 0.75 4.8 25A-A8P0N104 25B-A8P0N104 2.0 1.5 2.0 1.5 8.0 25A-A011N104 25B-A011N104 3.0 2.2 3.0 2.2 11.0 200...240V AC (-15%, +10%) – 1-Phase Input with EMC Filter, 0...230V 3-Phase Output 25A-A1P6N114 – 0.25 0.2 0.25 0.2 1.6 25A-A2P5N114 25B-A2P5N114 0.5 0.4 0.5 0.4 2.5 25A-A4P8N114 25B-A4P8N114 1.0 0.75 1.0 0.75 4.8 25A-A8P0N114 25B-A8P0N114 2.0 1.5 2.0 1.5 8.0 25A-A011N114 25B-A011N114 3.0 2.2 3.0 2.2 11.0 200...240V AC (-15%, +10%) – 3-Phase Input, 0...230V 3-Phase Output 25A-B1P6N104 – 0.25 0.2 0.25 0.2 1.6 25A-B2P5N104 25B-B2P5N104 0.5 0.4 0.5 0.4 2.5 25A-B5P0N104 25B-B5P0N104 1.0 0.75 1.0 0.75 5.0 25A-B8P0N104 25B-B8P0N104 2.0 1.5 2.0 1.5 8.0 25A-B011N104 25B-B011N104 3.0 2.2 3.0 2.2 11.0 25A-B017N104 25B-B017N104 5.0 4.0 5.0 4.0 17.5 25A-B024N104 25B-B024N104 7.5 5.5 7.5 5.5 24.0 25A-B032N104 25B-B032N104 10.0 7.5 10.0 7.5 32.2 25A-B048N104 25B-B048N104 15.0 11.0 10.0 7.5 48.3 25A-B062N104 25B-B062N104 20.0 15.0 15.0 11.0 62.1 380...480V AC (-15%, +10%) – 3-Phase Input, 0...460V 3-Phase Output(1) 25A-D1P4N104 25B-D1P4N104 0.5 0.4 0.5 25A-D2P3N104 25B-D2P3N104 1.0 0.75 1.0 25A-D4P0N104 25B-D4P0N104 2.0 1.5 2.0 25A-D6P0N104 25B-D6P0N104 3.0 2.2 3.0 25A-D010N104 25B-D010N104 5.0 4.0 5.0 25A-D013N104 25B-D013N104 7.5 5.5 7.5 25A-D017N104 25B-D017N104 10.0 7.5 10.0 25A-D024N104 25B-D024N104 15.0 11.0 15.0 25A-D030N104 25B-D030N104 20.0 15.0 15.0 14

0.4 0.75 1.5 2.2 4.0 5.5 7.5 11.0 11.0

1.4 2.3 4.0 6.0 10.5 13.0 17.0 24.0 30.0

Input Voltage Range

Total Watts Loss

Frame Size

85...132 85...132 85...132 85...132

20.0 27.0 53.0 67.0

A A B B

85...132 170...264 170...264 170...264 170...264

20.0 29.0 50.0 81.0 111.0

A A A B B

85...132 170...264 170...264 170...264 170...264

20.0 29.0 53.0 84.0 116.0

A A A B B

85...132 170...264 170...264 170...264 170...264 170...264 170...264 170...264 170...264 170...264

20.0 29.0 50.0 79.0 107.0 148.0 259.0 323.0 584.0 708.0

A A A A A B C D E E

323...528 323...528 323...528 323...528 323...528 323...528 323...528 323...528 323...528

27.0 37.0 62.0 86.0 129.0 170.0 221.0 303.0 387.0

A A A A B C C D D



Output Ratings Normal Duty Heavy Duty PowerFlex 523 PowerFlex 525 Output Catalog No. Catalog No. HP kW HP kW Current (A) 380...480V AC (-15%, +10%) – 3-Phase Input with EMC Filter, 0...460V 3-Phase Output 25A-D1P4N114 25B-D1P4N114 0.5 0.4 0.5 0.4 1.4 25A-D2P3N114 25B-D2P3N114 1.0 0.75 1.0 0.75 2.3 25A-D4P0N114 25B-D4P0N114 2.0 1.5 2.0 1.5 4.0 25A-D6P0N114 25B-D6P0N114 3.0 2.2 3.0 2.2 6.0 25A-D010N114 25B-D010N114 5.0 4.0 5.0 4.0 10.5 25A-D013N114 25B-D013N114 7.5 5.5 7.5 5.5 13.0 25A-D017N114 25B-D017N114 10.0 7.5 10.0 7.5 17.0 25A-D024N114 25B-D024N114 15.0 11.0 15.0 11.0 24.0 25A-D030N114 25B-D030N114 20.0 15.0 15.0 11.0 30.0 25A-D037N114 25B-D037N114 25.0 18.5 20.0 15.0 37.0 25A-D043N114 25B-D043N114 30.0 22.0 25.0 18.5 43.0 525...600V AC (-15%, +10%) – 3-Phase Input, 0...575V 3-Phase Output 25A-E0P9N104 25B-E0P9N104 0.5 0.4 0.5 0.4 0.9 25A-E1P7N104 25B-E1P7N104 1.0 0.75 1.0 0.75 1.7 25A-E3P0N104 25B-E3P0N104 2.0 1.5 2.0 1.5 3.0 25A-E4P2N104 25B-E4P2N104 3.0 2.2 3.0 2.2 4.2 25A-E6P6N104 25B-E6P6N104 5.0 4.0 5.0 4.0 6.6 25A-E9P9N104 25B-E9P9N104 7.5 5.5 7.5 5.5 9.9 25A-E012N104 25B-E012N104 10.0 7.5 10.0 7.5 12.0 25A-E019N104 25B-E019N104 15.0 11.0 15.0 11.0 19.0 25A-E022N104 25B-E022N104 20.0 15.0 15.0 11.0 22.0 25A-E027N104 25B-E027N104 25.0 18.5 20.0 15.0 27.0 25A-E032N104 25B-E032N104 30.0 22.0 25.0 18.5 32.0

Input Voltage Range

Total Watts Loss

Frame Size

323...528 323...528 323...528 323...528 323...528 323...528 323...528 323...528 323...528 323...528 323...528

27.0 37.0 63.0 88.0 133.0 175.0 230.0 313.0 402.0 602.0 697.0

A A A A B C C D D E E

446...660 446...660 446...660 446...660 446...660 446...660 446...660 446...660 446...660 446...660 446...660

22.0 32.0 50.0 65.0 95.0 138.0 164.0 290.0 336.0 466.0 562.0


(1) A non-filtered drive is not available for 380...480V AC 25 HP (18.5 kW) and 30 HP (22.0 kW) ratings. Filtered drives are available, however you must verify that the application will support a filtered drive.


15


Drive Dimensions and Weight Dimensions are in mm and (in.). Weights are in kg and (lb). C

A D

Esc

B

Sel

E

Frame Size A B C D E

A 72.0 (2.83) 87.0 (3.43) 109.0 (4.29) 130.0 (5.12) 185.0 (7.28)

B 152.0 (5.98) 180.0 (7.09) 220.0 (8.66) 260.0 (10.24) 300.0 (11.81)

C 172.0 (6.77) 172.0 (6.77) 184.0 (7.24) 212.0 (8.35) 279.0 (10.98)

D 57.5 (2.26) 72.5 (2.85) 90.5 (3.56) 116.0 (4.57) 160.0 (6.30)

Design Considerations Mounting Considerations • Mount the drive upright on a flat, vertical and level surface. Frame A B C D E

Screw Size M5 (#10...24) M5 (#10...24) M5 (#10...24) M5 (#10...24) M8 (5/16 in.)

Screw Torque 1.56...1.96 Nm (14...17 lb-in.) 1.56...1.96 Nm (14...17 lb-in.) 1.56...1.96 Nm (14...17 lb-in.) 2.45...2.94 Nm (22...26 lb-in.) 6.0...7.4 Nm (53...65 lb-in.)

• Protect the cooling fan by avoiding dust or metallic particles. • Do not expose to a corrosive atmosphere. • Protect from moisture and direct sunlight.

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E 140.0 (5.51) 168.0 (6.61) 207.0 (8.15) 247.0 (9.72) 280.0 (11.02)

Weight 1.1 (2.4) 1.6 (3.5) 2.3 (5.0) 3.9 (8.6) 12.9 (28.4)


Minimum Mounting Clearances See Dimensions and Weights on page 14 for mounting dimensions. Vertical

Vertical with Control Module Fan Kit

Vertical, Zero Stacking No clearance between drives.

50 mm (2.0 in.)

Esc

Sel

50 mm (2.0 in.)

25 mm (1.0 in.)

Esc

Esc

Sel

50 mm (2.0 in.)

50 mm (2.0 in.)(1)

Esc

Sel

Esc

Sel

Esc

Sel

50 mm (2.0 in.)

50 mm (2.0 in.)

50 mm (2.0 in.)(1) Esc

Sel

50 mm (2.0 in.)

Esc

Sel

(2)

50 mm (2.0 in.)(1) Esc

Sel

50 mm (2.0 in.)

50 mm (2.0 in.)(1)

Esc

Sel

25 mm (1.0 in.)

50 mm (2.0 in.)

50 mm (2.0 in.)

Sel

50 mm (2.0 in.)

Vertical, Zero Stacking with Control Module Fan Kit No clearance between drives.

(2) Esc Sel

Esc Sel

25 mm (1.0 in.)

50 mm (2.0 in.)

50 mm (2.0 in.)

Horizontal, Zero Stacking with Control Module Fan Kit No clearance between drives.

Horizontal with Control Module Fan Kit (1) For Frame E with Control Module Fan Kit only, clearance of 95 mm (3.7 in.) is required. (2) For Frame E with Control Module Fan Kit only, clearance of 12 mm (0.5 in.) is required.

Ambient Operating Temperatures See Accessories and Dimensions on page 32 for option kits. Ambient Temperature Mounting Vertical Vertical, Zero Stacking Horizontal with Control Module Fan Kit(4)(5) Horizontal, Zero Stacking with Control Module Fan Kit(4)(5)

Enclosure Rating(1) IP 20/Open Type IP 30/NEMA 1/UL Type 1 IP 20/Open Type IP 30/NEMA 1/UL Type 1 IP 20/Open Type IP 20/Open Type

Minimum

-20 °C (-4 °F)

Maximum (No Derate) 50 °C (122 °F) 45 °C (113 °F) 45 °C (113 °F) 40 °C (104 °F) 50 °C (122 °F)

Maximum (Derate)(2) 60 °C (140 °F) 55 °C (131 °F) 55 °C (131 °F) 50 °C (122 °F) –

Maximum with Control Module Fan Kit (Derate)(3)(5) 70 °C (158 °F) – 65 °C (149 °F) – 70 °C (158 °F)

45 °C (113 °F)

–

65 °C (149 °F)

(1) IP 30/NEMA 1/UL Type 1 rating requires installation of the PowerFlex 520-Series IP 30/NEMA 1/UL Type 1 option kit, catalog number 25-JBAx. (2) For catalogs 25x-D1P4N104 and 25x-E0P9N104, the temperature listed under the Max. (Derate) column is reduced by 5 °C (9 °F) for all mounting methods. (3) For catalogs 25x-D1P4N104 and 25x-E0P9N104, the temperature listed under the Max. with Control Module Fan Kit (Derate) column is reduced by 10 °C (18 °F) for vertical and vertical with zero stacking mounting methods only. (4) Catalogs 25x-D1P4N104 and 25x-E0P9N104 cannot be mounted using either of the horizontal mounting methods. (5) Requires installation of the PowerFlex 520-Series Control Module Fan Kit, catalog number 25-FANx-70C.


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Current Derating Curves Single Drive

Zero Stacking

120 with Control IP 30/NEMA 1 Module Fan Kit 110 100 90 IP 20/Open Type 80 70 60 50 40 30 35 40 45 50 55 60 65 70 75 80

120 with Control IP 30/NEMA 1 Module Fan Kit 110 100 90 IP 20/Open Type 80 70 60 50 40 30 35 40 45 50 55 60 65 70 75 80

Percentage of Rated Current (%)


Vertical Mounting

Ambient Temperature (°C)


Single Drive

Zero Stacking

120 with Control Module Fan Kit 110 100 90 IP 20/Open Type 80 70 60 50 40 30 35 40 45 50 55 60 65 70 75 80

120 with Control Module Fan Kit 110 100 90 IP 20/Open Type 80 70 60 50 40 30 35 40 45 50 55 60 65 70 75 80



Horizontal Mounting/Floor



Derating Guidelines for High Altitude The drive can be used without derating at a maximum altitude of 1000 m (3300 ft). If the drive is used above 1000 m (3300 ft): • Derate the maximum ambient temperature by 5 °C (9 °F) for every additional 1000 m (3300 ft), subject to limits listed in the Altitude Limit (Based on Voltage) table below. Or • Derate the output current by 10% for every additional 1000 m (3300 ft), subject to limits listed in the Altitude Limit (Based on Voltage) table below. Altitude Limit (Based on Voltage) Drive Rating 100...120V 1-Phase 200...240V 1-Phase 200...240V 3-Phase 380...480V 3-Phase 525...600V 3-Phase

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Center Ground (Wye Neutral) 6000 m 2000 m 6000 m 4000 m 2000 m

Corner Ground, Impedance Ground, or Ungrounded 6000 m 2000 m 2000 m 2000 m 2000 m



120 110 100 90 80 70 60 50 40

60 Ambient Temperature (°C)


High Altitude

0

1000

2000

3000

50 40 30 20

4000

0

1000

2000

3000

4000

Altitude (m)

Altitude (m)

Debris Protection Take precautions to prevent debris from falling through the vents of the drive housing during installation.

Storage • Store within an ambient temperature range of -40...85 °C(1). • Store within a relative humidity range of 0...95%, noncondensing. • Do not expose to a corrosive atmosphere. (1) The maximum ambient temperature for storing a Frame E drive is 70 °C.

AC Supply Source Considerations Ungrounded Distribution Systems ATTENTION: PowerFlex 520-Series drives contain protective MOVs that are referenced to ground. These devices must be disconnected if the drive is installed on an ungrounded or resistive grounded distribution system. ATTENTION: Removing MOVs in drives with an embedded filter will also disconnect the filter capacitor from earth ground.

Disconnecting MOVs To prevent drive damage, the MOVs connected to ground shall be disconnected if the drive is installed on an ungrounded distribution system (IT mains) where the line-to-ground voltages on any phase could exceed 125% of the nominal line-toline voltage. To disconnect these devices, remove the jumper shown in the diagrams below. 1. Turn the screw counterclockwise to loosen. 2. Pull the jumper completely out of the drive chassis. 3. Tighten the screw to keep it in place.


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Jumper Location (Typical) Power Module

IMPORTANT

Tighten screw after jumper removal.

Phase to Ground MOV Removal R/L1 Three-Phase AC Input S/L2 T/L3 Jumper

1

2

3

4

Input Power Conditioning The drive is suitable for direct connection to input power within the rated voltage of the drive (see Input Power Conditions on page 20). Listed in the Input Power Conditions table below are certain input power conditions which may cause component damage or reduction in product life. If any of these conditions exist, install one of the devices listed under the heading Corrective Action on the line side of the drive. IMPORTANT

Only one device per branch circuit is required. It should be mounted closest to the branch and sized to handle the total current of the branch circuit.

Input Power Conditions Input Power Condition Low Line Impedance (less than 1% line reactance) Greater than 120 kVA supply transformer Line has power factor correction capacitors Line has frequent power interruptions Line has intermittent noise spikes in excess of 6000V (lightning) Phase to ground voltage exceeds 125% of normal line to line voltage Ungrounded distribution system B-phase grounded distribution system 240V open delta configuration (stinger leg)(1)

20

Corrective Action • Install Line Reactor(2) • or Isolation Transformer • Install Line Reactor(2) • or Isolation Transformer • Remove MOV jumper to ground. • or Install Isolation Transformer with grounded secondary if necessary. • Install Line Reactor(2)



(1) For drives applied on an open delta with a middle phase grounded neutral system, the phase opposite the phase that is tapped in the middle to the neutral or earth is referred to as the “stinger leg,” “high leg,” “red leg,” etc. This leg should be identified throughout the system with red or orange tape on the wire at each connection point. The stinger leg should be connected to the center Phase B on the reactor. See Bulletin 1321-3R Series Line Reactors on page 37 for specific line reactor part numbers. (2) See Accessories and Dimensions on page 32 for accessory ordering information.

General Grounding Requirements The drive Safety Ground - (PE) must be connected to system ground. Ground impedance must conform to the requirements of national and local industrial safety regulations and/or electrical codes. The integrity of all ground connections should be periodically checked. Typical Grounding

Esc

Sel

R/L1 S/L2 T/L3

U/T1 V/T2 W/T3

SHLD

Ground Fault Monitoring If a system ground fault monitor (RCD) is to be used, only Type B (adjustable) devices should be used to avoid nuisance tripping.

Safety Ground -

(PE)

This is the safety ground for the drive that is required by code. One of these points must be connected to adjacent building steel (girder, joist), a floor ground rod or bus bar. Grounding points must comply with national and local industrial safety regulations and/or electrical codes.

Motor Ground The motor ground must be connected to one of the ground terminals on the drive.

Shield Termination - SHLD Either of the safety ground terminals located on the power terminal block provides a grounding point for the motor cable shield. The motor cable shield connected to one of these terminals (drive end) should also be connected to the motor frame (motor end). Use a shield terminating or EMI clamp to connect the shield to the safety ground terminal. The earthing plate or conduit box option may be used with a cable clamp for a grounding point for the cable shield. When shielded cable is used for control and signal wiring, the shield should be grounded at the source end only, not at the drive end.


21


RFI Filter Grounding Using a drive with filter may result in relatively high ground leakage currents. Therefore, the filter must only be used in installations with grounded AC supply systems and be permanently installed and solidly grounded (bonded) to the building power distribution ground. Ensure that the incoming supply neutral is solidly connected (bonded) to the same building power distribution ground. Grounding must not rely on flexible cables and should not include any form of plug or socket that would permit inadvertent disconnection. Some local codes may require redundant ground connections. The integrity of all connections should be periodically checked.

Power Wiring ATTENTION: National Codes and standards (NEC, VDE, BSI, etc.) and local codes outline provisions for safely installing electrical equipment. Installation must comply with specifications regarding wire types, conductor sizes, branch circuit protection and disconnect devices. Failure to do so may result in personal injury and/or equipment damage. ATTENTION: To avoid a possible shock hazard caused by induced voltages, unused wires in the conduit must be grounded at both ends. For the same reason, if a drive sharing a conduit is being serviced or installed, all drives using this conduit should be disabled. This will help minimize the possible shock hazard from “cross coupled” power leads.

Motor Cable Types Acceptable for 100...600 Volt Installations A variety of cable types are acceptable for drive installations. For many installations, unshielded cable is adequate, provided it can be separated from sensitive circuits. As an approximate guide, allow a spacing of 0.3 m (1 ft) for every 10 m (32.8 ft) of length. In all cases, long parallel runs must be avoided. Do not use cable with an insulation thickness less than 15 mils (0.4 mm/0.015 in.). Do not route more than three sets of motor leads in a single conduit to minimize “cross talk”. If more than three drive/motor connections per conduit are required, shielded cable must be used. UL installations above 50 °C ambient must use 600V, 90 °C wire. UL installations in 50 °C ambient must use 600V, 75 °C or 90 °C wire. UL installations in 40 °C ambient should use 600V, 75 °C or 90 °C wire. Use copper wire only. Wire gauge requirements and recommendations are based on 75 °C. Do not reduce wire gauge when using higher temperature wire. Unshielded THHN, THWN or similar wire is acceptable for drive installation in dry environments provided adequate free air space and/or conduit fill rates limits are provided. Any wire chosen must have a minimum insulation thickness of 15 mils and should not have large variations in insulation concentricity.

ATTENTION: Do not use THHN or similarly coated wire in wet areas.

22



Shielded/Armored Cable Shielded cable contains all of the general benefits of multi-conductor cable with the added benefit of a copper braided shield that can contain much of the noise generated by a typical AC Drive. Strong consideration for shielded cable should be given in installations with sensitive equipment such as weigh scales, capacitive proximity switches and other devices that may be affected by electrical noise in the distribution system. Applications with large numbers of drives in a similar location, imposed EMC regulations or a high degree of communications / networking are also good candidates for shielded cable. Shielded cable may also help reduce shaft voltage and induced bearing currents for some applications. In addition, the increased impedance of shielded cable may help extend the distance that the motor can be located from the drive without the addition of motor protective devices such as terminator networks. Refer to Reflected Wave in “Wiring and Grounding Guide, (PWM) AC Drives,” publication DRIVES-IN001. Consideration should be given to all of the general specifications dictated by the environment of the installation, including temperature, flexibility, moisture characteristics and chemical resistance. In addition, a braided shield should be included and be specified by the cable manufacturer as having coverage of at least 75%. An additional foil shield can greatly improve noise containment. A good example of recommended cable is Belden® 295xx (xx determines gauge). This cable has four (4) XLPE insulated conductors with a 100% coverage foil and an 85% coverage copper braided shield (with drain wire) surrounded by a PVC jacket. Other types of shielded cable are available, but the selection of these types may limit the allowable cable length. Particularly, some of the newer cables twist 4 conductors of THHN wire and wrap them tightly with a foil shield. This construction can greatly increase the cable charging current required and reduce the overall drive performance. Unless specified in the individual distance tables as tested with the drive, these cables are not recommended and their performance against the lead length limits supplied is not known. Recommended Shielded Wire Location Rating/Type Standard (Option 1) 600V, 90 °C (194 °F) XHHW2/RHW-2 Anixter B209500-B209507, Belden 29501-29507, or equivalent Standard (Option 2) Tray rated 600V, 90 °C (194 °F) RHH/RHW-2 Anixter OLF-7xxxxx or equivalent

Class I & II; Division I & II

Tray rated 600V, 90 °C (194 °F) RHH/RHW-2 Anixter 7V-7xxxx-3G or equivalent

Description • Four tinned copper conductors with XLPE insulation. • Copper braid/aluminum foil combination shield and tinned copper drain wire. • PVC jacket. • Three tinned copper conductors with XLPE insulation. • 5 mil single helical copper tape (25% overlap min.) with three bare copper grounds in contact with shield. • PVC jacket. • Three bare copper conductors with XLPE insulation and impervious corrugated continuously welded aluminum armor. • Black sunlight resistant PVC jacket overall. • Three copper grounds on #10 AWG and smaller.

Reflected Wave Protection The drive should be installed as close to the motor as possible. Installations with long motor cables may require the addition of external devices to limit voltage reflections at the motor (reflected wave phenomena). Refer to Reflected Wave in “Wiring and Grounding Guide, (PWM) AC Drives,” publication DRIVES-IN001. The reflected wave data applies to all carrier frequencies 2...16 kHz. For 240V ratings and lower, reflected wave effects do not need to be considered.


23


Output Disconnect The drive is intended to be commanded by control input signals that will start and stop the motor. A device that routinely disconnects then reapplies output power to the motor for the purpose of starting and stopping the motor should not be used. If it is necessary to disconnect power to the motor with the drive outputting power, an auxiliary contact should be used to simultaneously disable drive (Aux Fault or Coast-to-Stop). Power Terminal Block Wire Specifications Frame

Maximum Wire Size(1) 2

Minimum Wire Size(1)

Torque

2

1.76...2.16 Nm (15.6...19.1 lb-in.)

2

A

5.3 mm (10 AWG)

B

8.4 mm2 (8 AWG)

0.8 mm (18 AWG) 2.1 mm (14 AWG)

1.76...2.16 Nm (15.6...19.1 lb-in.)

C

8.4 mm2 (8 AWG)

2.1 mm2 (14 AWG)

1.76...2.16 Nm (15.6...19.1 lb-in.)

D

2

13.3 mm (6 AWG)

2

5.3 mm (10 AWG)

1.76...2.16 Nm (15.6...19.1 lb-in.)

E

26.7 mm2 (3 AWG)

8.4 mm2 (8 AWG)

3.09...3.77 Nm (27.3...33.4 lb-in.)

(1) Maximum/minimum sizes that the terminal block will accept – these are not recommendations.

Common Bus/Precharge Notes If drives are used with a disconnect switch to the common DC bus, then an auxiliary contact on the disconnect must be connected to a digital input of the drive.

I/O Wiring Motor Start/Stop Precautions ATTENTION: A contactor or other device that routinely disconnects and reapplies the AC line to the drive to start and stop the motor can cause drive hardware damage. The drive is designed to use control input signals that will start and stop the motor. If used, the input device must not exceed one operation per minute or drive damage can occur. ATTENTION: The drive start/stop control circuitry includes solid-state components. If hazards due to accidental contact with moving machinery or unintentional flow of liquid, gas or solids exist, an additional hardwired stop circuit may be required to remove the AC line to the drive. When the AC line is removed, there will be a loss of any inherent regenerative braking effect that might be present - the motor will coast to a stop. An auxiliary braking method may be required. Alternatively, use the drive’s safety input function. Important points to remember about I/O wiring: • Always use copper wire. • Wire with an insulation rating of 600V or greater is recommended. • Control and signal wires should be separated from power wires by at least 0.3 m (1 ft). IMPORTANT

I/O terminals labeled “Common” are not referenced to the safety ground (PE) terminal and are designed to greatly reduce common mode interference.

ATTENTION: Driving the 4-20 mA analog input from a voltage source could cause component damage. Verify proper configuration prior to applying input signals.

24



Signal and Control Wire Types Recommendations are for 50 °C ambient temperature. 75 °C wire must be used for 60 °C ambient temperature. 90 °C wire must be used for 70 °C ambient temperature. Recommended Signal Wire Signal Type/Where Used

Belden Wire Type(s)(or equivalent)(1)

Description

Min. Insulation Rating

Analog I/O & PTC

8760/9460

0.750 mm2 (18 AWG), twisted pair, 100% shield with drain(2)

Remote Pot

8770

0.750 mm2 (18 AWG), 3 conductor, shielded

300V, 60 °C (140 °F)

Encoder/Pulse I/O

9728/9730

0.196 mm2 (24 AWG), individually shielded pairs

(1) Stranded or solid wire. (2) If the wires are short and contained within a cabinet which has no sensitive circuits, the use of shielded wire may not be necessary, but is always recommended.

Recommended Control Wire for Digital I/O Type

Wire Type(s)

Description

Unshielded

Per US NEC or applicable national or local code –

Shielded

Multi-conductor shielded cable such as Belden 8770 (or equivalent)

Min. Insulation Rating

0.750 mm2 (18 AWG), 3 conductor, shielded.

300V, 60 °C (140 °F)

Maximum Control Wire Recommendation Do not exceed control wiring length of 30 m (100 ft). Control signal cable length is highly dependent on electrical environment and installation practices. To improve noise immunity, the I/O terminal block Common may be connected to ground terminal/protective earth. If using the RS485 (DSI) port, I/O Terminal C1 should also be connected to ground terminal/protective earth. Additionally, communication noise immunity can also be improved by connecting I/O Terminal C2 to ground terminal/protective earth. Control I/O Terminal Block Wire Specifications Frame A...E

Maximum Wire Size(1) 2 (16 AWG)

1.3 mm

Minimum Wire Size(1)

Torque

0.13 mm2 (26 AWG)

0.71...0.86 Nm (6.2...7.6 lb-in.)

(1) Maximum/minimum sizes that the terminal block will accept – these are not recommendations.

Machinery Directive (2006/42/EC) • EN ISO 13849-1 – Safety of machinery – Safety related parts of control systems -Part 1: General principles for design. • EN 62061 – Safety of machinery – Functional safety of safety-related electrical, electronic and programmable electronic control systems. • EN 60204-1 – Safety of machinery – Electrical equipment of machines - Part 1: General requirements. • EN 61800-5-2 – Adjustable speed electrical power drive systems - Part 5-2: Safety requirement – Functional.


25


Connections and Grounding Shielded enclosure(1) Esc

IP 30/NEMA 1/UL Type 1 option kit or EMC kit

Sel

EMI fittings and metal conduit EMI filter L1 L1' L2 L2' L3 L3'

R/L1 S/L2 T/L3

Enclosure ground connection

U/T1 V/T2 W/T3

Shielded motor cable

Building structure steel

(1) Some installations require a shielded enclosure. Keep wire length as short as possible between the enclosure entry point and the EMI filter.

PowerFlex 520-Series RF Emission Compliance and Installation Requirements Standard/Limits

Filter Type

EN61800-3 Category C1 EN61000-6-3 CISPR11 Group 1 Class B

EN61800-3 Category C2 EN61000-6-4 CISPR11 Group 1 Class A (Input power ≤ 20 kVA)

EN61800-3 Category C3 (I ≤ 100 A) CISPR11 Group 1 Class A (Input power > 20 kVA)

Internal

–

10 m (33 ft)

20 m (66 ft)

External(1)

30 m (16 ft)

100 m (328 ft)

100 m (328 ft)

(1) See Accessory Dimensions on page 39 for more information on optional external filters.

26



Fuses and Circuit Breaker Ratings The PowerFlex 520-Series drive does not provide branch short circuit protection. This product should be installed with either input fuses or an input circuit breaker. National and local industrial safety regulations and/or electrical codes may determine additional requirements for these installations. The tables on pages 28...31 provide drive ratings and recommended AC line input fuse and circuit breaker information. Both types of short circuit protection are acceptable for UL and IEC requirements. Sizes listed are the recommended sizes based on 40 °C (104 °F) and the U.S. N.E.C. Other country, state or local codes may require different ratings.

Fusing The recommended fuse types are listed in the tables found on pages 28...31. If available current ratings do not match those listed in the tables provided, choose the next higher fuse rating. • IEC – BS88 (British Standard) Parts 1 & 2(1), EN60269-1, Parts 1 & 2, type GG or equivalent should be used. • UL – UL Class CC, T, RK1, or J should be used. (1) Typical designations include, but may not be limited to the following; Parts 1 & 2: AC, AD, BC, BD, CD, DD, ED, EFS, EF, FF, FG, GF, GG, GH.

Circuit Breakers The “non-fuse” listings in the tables found on pages 28...31 include inverse time circuit breakers, instantaneous trip circuit breakers (motor circuit protectors) and 140M self-protected combination motor controllers. If one of these is chosen as the desired protection method, the following requirements apply: • IEC – Both types of circuit breakers and 140M self-protected combination motor controllers are acceptable for IEC installations. • UL – Only inverse time circuit breakers and the specified 140M selfprotected combination motor controllers are acceptable for UL installations. Bulletin 140M (Self-Protected Combination Controller)/UL489 Circuit Breakers When using Bulletin 140M or UL489 rated circuit breakers, the guidelines listed below must be followed in order to meet the NEC requirements for branch circuit protection. • Bulletin 140M can be used in single motor applications. • Bulletin 140M can be used up stream from the drive without the need for fuses.


27


(1) (2) (3) (4) (5)

0.2 0.2 0.4 0.4 0.75 0.75 1.5 1.5 2.2 2.2

1.6 2.5 4.8 6.0

Amps 1.6 1.6 2.5 2.5 4.8 4.8 8.0 8.0 11.0 11.0

1.4 1.4 1.7 1.7 2.8 2.8 4.8 4.8 6.0 6.0

A A B B

100-C09 100-C12 100-C23 100-C23

10 16 25 32

16 20 40 50

140U-D6D2-B80 140U-D6D2-C12 140U-D6D2-C25 140U-D6D2-C30

140M-C2E-B63 140M-C2E-C10 140M-D8E-C20 140M-F8E-C25

Fuses (Rating) Circuit Breakers Min. Max. 140U/140G 140M

IEC Applications (Non-UL)

CLASS RK5, CC, J, or T / DLS-R-15 CLASS RK5, CC, J, or T / DLS-R-20 CLASS RK5, CC, J, or T / DLS-R-40 CLASS RK5, CC, J, or T / DLS-R-50

Fuses (Max. Rating) Class / Catalog No.

UL Applications

Max Amps(1) 5.3 5.3 6.5 6.5 10.7 10.7 18.0 18.0 22.9 22.9 A 100-C09 6 A 100-C09 6 A 100-C09 10 A 100-C09 10 A 100-C12 16 A 100-C12 16 B 100-C23 25 B 100-C23 25 B 100-C37 32 B 100-C37 32

10 10 16 16 25 25 40 40 50 50

140U-D6D2-C10 140U-D6D2-C10 140U-D6D2-C10 140U-D6D2-C10 140U-D6D2-C15 140U-D6D2-C15 140U-D6D2-C25 140U-D6D2-C25 140G-G6C3-C35 140G-G6C3-C35

140M-C2E-B63 140M-C2E-B63 140M-C2E-C10 140M-C2E-C10 140M-C2E-C16 140M-C2E-C16 140M-F8E-C25 140M-F8E-C25 140M-F8E-C25 140M-F8E-C25



CLASS RK5, CC, J, or T / DLS-R-15 CLASS RK5, CC, J, or T / DLS-R-15 CLASS RK5, CC, J, or T / DLS-R-15 CLASS RK5, CC, J, or T / DLS-R-15 CLASS RK5, CC, J, or T / DLS-R-25 CLASS RK5, CC, J, or T / DLS-R-25 CLASS CC, J, or T / 40 CLASS CC, J, or T / 40 CLASS CC, J, or T / 50 CLASS CC, J, or T / 50


UL Applications

200...240V 1-Phase Input Protection Devices – Frames A...B Input Ratings

0.8 1.3 2.5 3.2

Max Amps(1) 6.4 9.6 19.2 24.0

Input Ratings

When the drive is controlling motors with lower amp ratings, refer to the drive nameplate for drive intput current rating. The AIC ratings of the Bulletin 140M Motor Protector Circuit Breakers may vary. See Bulletin 140M Motor Protection Circuit Breakers Application Ratings. Bulletin 140M with adjustable current range should have the current trip set to the minimum range that the device will not trip. Manual Self-Protected (Type E) Combination Motor Controller, UL listed for 480Y/277 and 600Y/347 AC input. Not UL listed for use on 480V or 600V Delta/Delta, corner ground, or high-resistance ground systems. Circuit breaker selection is not available for this drive rating.

0.25 0.25 0.5 0.5 1.0 1.0 2.0 2.0 3.0 3.0

– – 25B-A2P5N104 25B-A2P5N114 25B-A4P8N104 25B-A4P8N114 25B-A8P0N104 25B-A8P0N114 25B-A011N104 25B-A011N114

25A-A1P6N104 25A-A1P6N114 25A-A2P5N104 25A-A2P5N114 25A-A4P8N104 25A-A4P8N114 25A-A8P0N104 25A-A8P0N114 25A-A011N104 25A-A011N114

0.2 0.2 0.4 0.4 0.75 0.75 1.5 1.5 2.2 2.2

ND HD HP kW HP kW

PF 525

PF 523

0.25 0.25 0.5 0.5 1.0 1.0 2.0 2.0 3.0 3.0

Output Ratings

0.2 0.4 0.75 1.1

Catalog No.

0.25 0.5 1.0 1.5

– 25B-V2P5N104 25B-V4P8N104 25B-V6P0N104

25A-V1P6N104 25A-V2P5N104 25A-V4P8N104 25A-V6P0N104

0.2 0.4 0.75 1.1

ND HD HP kW HP kW

PF 525

PF 523

0.25 0.5 1.0 1.5

Output Ratings

Catalog No.

100...120V 1-Phase Input Protection Devices – Frames A...B Frame Size Frame Size

kVA kVA

Contactor Catalog No. Contactor Catalog No.

28 Amps

Fuses and Circuit Breakers for PowerFlex 520-Series Drives

140M-C2E-B63 140M-C2E-C10 140M-D8E-C20 140M-F8E-C25

140U-D6D2-C10 140U-D6D2-C10 140U-D6D2-C10 140U-D6D2-C10 140U-D6D2-C15 140U-D6D2-C15 140U-D6D2-C25 140U-D6D2-C25 –(5) –(5)

140M-C2E-B63 140M-C2E-B63 140M-C2E-C10 140M-C2E-C10 140M-C2E-C16 140M-C2E-C16 140M-F8E-C25 140M-F8E-C25 140M-F8E-C25 140M-F8E-C25

Circuit Breakers 140U/140G 140M(2)(3)(4)

140U-D6D2-B80 140U-D6C2-C12 140U-D6D2-C25 140U-D6D2-C30


Min. Enclosure Vol. (in.3) – – – – – – – – – –

Min. Enclosure Vol. (in.3) – – – –


0.2 0.4 0.75 1.5 2.2 4.0 5.5 7.5 7.5 11.0

1.6 2.5 5.0 8.0 11.0 17.5 24.0 32.2 48.3 62.1

kVA 0.9 1.2 2.7 4.3 6.3 9.6 12.2 15.9 20.1 25.6

Max Amps(2) 1.9 2.7 5.8 9.5 13.8 21.1 26.6 34.8 44.0 56.0

Input Ratings

A A A A A B C D E E

Frame Size 100-C09 100-C09 100-C09 100-C12 100-C23 100-C23 100-C37 100-C43 100-C60 100-C72

3 6 10 16 20 32 35 45 63 70

6 6 16 20 32 45 63 70 90 125

140U-D6D3-B30 140U-D6D3-B40 140U-D6D3-B80 140U-D6D3-C10 140U-D6D3-C15 140U-D6D3-C25 140G-G6C3-C35 140G-G6C3-C60 140G-G6C3-C70 140G-G6C3-C90

140M-C2E-B25 140M-C2E-B40 140M-C2E-B63 140M-C2E-C10 140M-C2E-C16 140M-F8E-C25 140M-F8E-C32 140M-F8E-C45 140M-F8E-C45 –(7)



CLASS RK5, CC, J, or T / DLS-R-15 CLASS RK5, CC, J, or T / DLS-R-6 CLASS RK5, CC, J, or T / DLS-R-15 CLASS RK5, CC, J, or T / DLS-R-20 CLASS RK5, CC, J, or T / DLS-R-30 CLASS CC, J, or T / 45 CLASS CC, J, or T / 60 CLASS RK5, CC, J, or T / DLS-R-70 CLASS CC, J, or T / 90 CLASS CC, J, or T / 125


UL Applications

200...240V 3-Phase Input Protection Devices – Frames A...E Contactor Catalog No.

140U-D6D3-B30 140U-D6D3-B40 140U-D6D3-B80 140U-D6D3-C10 140U-D6D3-C15 140U-D6D3-C25 –(7) –(7) –(7) –(7)

140M-C2E-B25 140M-C2E-B40 140M-C2E-B63 140M-C2E-C10 140M-C2E-C16 140M-F8E-C25 140M-F8E-C32 140M-F8E-C45 140M-F8E-C45 –


Min. Enclosure Vol. (in.3) – – – – – – – – 1416.0(6) –

Normal and Heavy Duty ratings are available for this drive. When the drive is controlling motors with lower amp ratings, refer to the drive nameplate for drive intput current rating. The AIC ratings of the Bulletin 140M Motor Protector Circuit Breakers may vary. See Bulletin 140M Motor Protection Circuit Breakers Application Ratings. Bulletin 140M with adjustable current range should have the current trip set to the minimum range that the device will not trip. Manual Self-Protected (Type E) Combination Motor Controller, UL listed for 480Y/277 and 600Y/347 AC input. Not UL listed for use on 480V or 600V Delta/Delta, corner ground, or high-resistance ground systems. When using a Manual Self-Protected (Type E) Combination Motor Controller with this drive power rating, the drive must be installed in a ventilated or non-ventilated enclosure with the minimum volume specified in this column. Application specific thermal considerations may require a larger enclosure. (7) Circuit breaker selection is not available for this drive rating.

(1) (2) (3) (4) (5) (6)

0.25 0.5 1.0 2.0 3.0 5.0 7.5 10.0 10.0 15.0

– 25B-B2P5N104 25B-B5P0N104 25B-B8P0N104 25B-B011N104 25B-B017N104 25B-B024N104 25B-B032N104 25B-B048N104 25B-B062N104

25A-B1P6N104 25A-B2P5N104 25A-B5P0N104 25A-B8P0N104 25A-B011N104 25A-B017N104 25A-B024N104 25A-B032N104 25A-B048N104 25A-B062N104

0.2 0.4 0.75 1.5 2.2 4.0 5.5 7.5 11.0 15.0

ND HD HP kW HP kW

PF 525

PF 523

0.25 0.5 1.0 2.0 3.0 5.0 7.5 10.0 15.0 20.0

Output Ratings

Catalog No.(1)

Amps

Fuses and Circuit Breakers for PowerFlex 520-Series Drives (continued)



29


0.4 0.4 0.75 0.75 1.5 1.5 2.2 2.2 4.0 4.0 5.5 5.5 7.5 7.5 11.0 11.0 11.0 11.0 15.0 18.5

1.4 1.4 2.3 2.3 4.0 4.0 6.0 6.0 10.5 10.5 13.0 13.0 17.0 17.0 24.0 24.0 30.0 30.0 37.0 43.0

1.7 1.7 2.9 2.9 5.2 5.2 6.9 6.9 12.6 12.6 14.1 14.1 16.8 16.8 24.1 24.1 30.2 30.2 30.8 35.6

Max Amps(2) 1.9 1.9 3.2 3.2 5.7 5.7 7.5 7.5 13.8 13.8 15.4 15.4 18.4 18.4 26.4 26.4 33.0 33.0 33.7 38.9

Input Ratings kVA

A A A A A A A A B B C C C C D D D D E E

100-C09 100-C09 100-C09 100-C09 100-C09 100-C09 100-C09 100-C09 100-C23 100-C23 100-C23 100-C23 100-C23 100-C23 100-C37 100-C37 100-C43 100-C43 100-C43 100-C60

3 3 6 6 10 10 10 10 20 20 20 20 25 25 35 35 45 45 45 50

6 6 10 10 16 16 16 16 32 32 35 35 40 40 63 63 70 70 70 80

140U-D6D3-B30 140U-D6D3-B30 140U-D6D3-B60 140U-D6D3-B60 140U-D6D3-B60 140U-D6D3-B60 140U-D6D3-C10 140U-D6D3-C10 140U-D6D3-C15 140U-D6D3-C15 140U-D6D3-C25 140U-D6D3-C25 140U-D6D3-C25 140U-D6D3-C25 140G-G6C3-C40 140G-G6C3-C40 140G-G6C3-C50 140G-G6C3-C50 140G-G6C3-C50 140G-G6C3-C60

140M-C2E-B25 140M-C2E-B25 140M-C2E-B40 140M-C2E-B40 140M-C2E-B63 140M-C2E-B63 140M-C2E-C10 140M-C2E-C10 140M-C2E-C16 140M-C2E-C16 140M-D8E-C20 140M-D8E-C20 140M-D8E-C20 140M-D8E-C20 140M-F8E-C32 140M-F8E-C32 140M-F8E-C45 140M-F8E-C45 140M-F8E-C45 140M-F8E-C45



CLASS RK5, CC, J, or T / DLS-R-6 CLASS RK5, CC, J, or T / DLS-R-6 CLASS RK5, CC, J, or T / DLS-R-10 CLASS RK5, CC, J, or T / DLS-R-10 CLASS RK5, CC, J, or T / DLS-R-15 CLASS RK5, CC, J, or T / DLS-R-15 CLASS RK5, CC, J, or T / DLS-R-15 CLASS RK5, CC, J, or T / DLS-R-15 CLASS RK5, CC, J, or T / DLS-R-30 CLASS RK5, CC, J, or T / DLS-R-30 CLASS CC, J, or T / 35 CLASS CC, J, or T / 35 CLASS CC, J, or T / 40 CLASS CC, J, or T / 40 CLASS CC, J, or T / 60 CLASS CC, J, or T / 60 CLASS CC, J, or T / 70 CLASS CC, J, or T / 70 CLASS CC, J, or T / 70 CLASS CC, J, or T / 80


UL Applications

–(7) –(7) –(7) –(7) –(7) –(7) –(7) –(7) –(7) –(7) –(7) –(7) –(7) –(7) –(7) –(7) –(7) –(7) –(7) –(7)

140M-C2E-B25 140M-C2E-B25 140M-C2E-B40 140M-C2E-B40 140M-C2E-B63 140M-C2E-B63 140M-C2E-C10 140M-C2E-C10 140M-C2E-C16 140M-C2E-C16 140M-D8E-C20 140M-D8E-C20 140M-D8E-C20 140M-D8E-C20 140M-F8E-C32 140M-F8E-C32 140M-F8E-C45 140M-F8E-C45 140M-F8E-C45 140M-F8E-C45


Min. Enclosure Vol. (in.3) – – – – – – – – – – – – – – 656.7(6) 656.7(6) 656.7(6) 656.7(6) – –

Normal and Heavy Duty ratings are available for this drive When the drive is controlling motors with lower amp ratings, refer to the drive nameplate for drive intput current rating. The AIC ratings of the Bulletin 140M Motor Protector Circuit Breakers may vary. See Bulletin 140M Motor Protection Circuit Breakers Application Ratings. Bulletin 140M with adjustable current range should have the current trip set to the minimum range that the device will not trip. Manual Self-Protected (Type E) Combination Motor Controller, UL listed for 480Y/277 and 600Y/347 AC input. Not UL listed for use on 480V or 600V Delta/Delta, corner ground, or high-resistance ground systems. When using a Manual Self-Protected (Type E) Combination Motor Controller with this drive power rating, the drive must be installed in a ventilated or non-ventilated enclosure with the minimum volume specified in this column. Application specific thermal considerations may require a larger enclosure. (7) Circuit breaker selection is not available for this drive rating.

(1) (2) (3) (4) (5) (6)

0.5 0.5 1.0 1.0 2.0 2.0 3.0 3.0 5.0 5.0 7.5 7.5 10.0 10.0 15.0 15.0 15.0 15.0 20.0 25.0

25B-D1P4N104 25B-D1P4N114 25B-D2P3N104 25B-D2P3N114 25B-D4P0N104 25B-D4P0N114 25B-D6P0N104 25B-D6P0N114 25B-D010N104 25B-D010N114 25B-D013N104 25B-D013N114 25B-D017N104 25B-D017N114 25B-D024N104 25B-D024N114 25B-D030N104 25B-D030N114 25B-D037N114 25B-D043N114

25A-D1P4N104 25A-D1P4N114 25A-D2P3N104 25A-D2P3N114 25A-D4P0N104 25A-D4P0N114 25A-D6P0N104 25A-D6P0N114 25A-D010N104 25A-D010N114 25A-D013N104 25A-D013N114 25A-D017N104 25A-D017N114 25A-D024N104 25A-D024N114 25A-D030N104 25A-D030N114 25A-D037N114 25A-D043N114

0.4 0.4 0.75 0.75 1.5 1.5 2.2 2.2 4.0 4.0 5.5 5.5 7.5 7.5 11.0 11.0 15.0 15.0 18.5 22.0

ND HD HP kW HP kW

PF 525

PF 523

0.5 0.5 1.0 1.0 2.0 2.0 3.0 3.0 5.0 5.0 7.5 7.5 10.0 10.0 15.0 15.0 20.0 20.0 25.0 30.0

Output Ratings

Catalog No.(1) Frame Size


30 Amps



0.4 0.75 1.5 2.2 4.0 5.5 7.5 11.0 11.0 15.0 18.5

0.9 1.7 3.0 4.2 6.6 9.9 12.0 19.0 22.0 27.0 32.0

kVA 1.4 2.6 4.3 6.1 9.1 12.8 15.4 27.4 31.2 28.2 33.4

Max Amps(2) 1.2 2.3 3.8 5.3 8.0 11.2 13.5 24.0 27.3 24.7 29.2

Input Ratings

6 6 10 16 20 25 32 50 63 50 63

140U-D6D3-B20 140U-D6D3-B30 140U-D6D3-B50 140U-D6D3-B80 140U-D6D3-C10 140U-D6D3-C15 140U-D6D3-C20 140G-G6C3-C30 140G-G6C3-C35 140G-G6C3-C35 140G-G6C3-C50

140M-C2E-B25 140M-C2E-B25 140M-C2E-B40 140M-C2E-B63 140M-C2E-C10 140M-C2E-C16 140M-C2E-C16 140M-F8E-C25 140M-F8E-C32 140M-F8E-C32 140M-F8E-C32



A 100-C09 3 A 100-C09 3 A 100-C09 6 A 100-C09 10 B 100-C09 10 C 100-C16 16 C 100-C23 20 D 100-C30 32 D 100-C30 35 E 100-C30 35 E 100-C37 40

Frame Size

CLASS RK5, CC, J, or T / DLS-R-6 CLASS RK5, CC, J, or T / DLS-R-6 CLASS RK5, CC, J, or T / DLS-R-10 CLASS RK5, CC, J, or T / DLS-R-15 CLASS RK5, CC, J, or T / DLS-R-20 CLASS RK5, CC, J, or T / DLS-R-25 CLASS RK5, CC, J, or T / DLS-R-30 CLASS CC, J, or T / 50 CLASS CC, J, or T / 60 CLASS CC, J, or T / 50 CLASS CC, J, or T / 60


UL Applications


–(8) –(8) –(8) –(8) –(8) –(8) –(8) –(8) –(8) –(8) –(8)

Min. Enclosure Vol. (in.3) 140M-C2E-B25 – 140M-C2E-B25 – 140M-C2E-B40 – 140M-D8E-B63 – 140M-D8E-C10 – 140M-D8E-C16(6) – 140M-D8E-C16 – 140M-F8E-C25 656.7(7) 140M-F8E-C32 656.7(7) 140M-F8E-C32 1416.0(7) 140M-F8E-C32 1416.0(7)


Normal and Heavy Duty ratings are available for this drive When the drive is controlling motors with lower amp ratings, refer to the drive nameplate for drive intput current rating. The AIC ratings of the Bulletin 140M Motor Protector Circuit Breakers may vary. See Bulletin 140M Motor Protection Circuit Breakers Application Ratings. Bulletin 140M with adjustable current range should have the current trip set to the minimum range that the device will not trip. Manual Self-Protected (Type E) Combination Motor Controller, UL listed for 480Y/277 and 600Y/347 AC input. Not UL listed for use on 480V or 600V Delta/Delta, corner ground, or high-resistance ground systems. When used with the 140M circuit breaker, the 25A-E9P9104 must be installed in a ventilated or non-ventilated enclosure with the minimum size of 457.2 x 457.2 x 269.8 mm (18 x 18 x 10.62 in.). When using a Manual Self-Protected (Type E) Combination Motor Controller with this drive power rating, the drive must be installed in a ventilated or non-ventilated enclosure with the minimum volume specified in this column. Application specific thermal considerations may require a larger enclosure. (8) Circuit breaker selection is not available for this drive rating.

(1) (2) (3) (4) (5) (6) (7)

0.5 1.0 2.0 3.0 5.0 7.5 10.0 15.0 15.0 20.0 25.0

25B-E0P9N104 25B-E1P7N104 25B-E3P0N104 25B-E4P2N104 25B-E6P6N104 25B-E9P9N104 25B-E012N104 25B-E019N104 25B-E022N104 25B-E027N104 25B-E032N104

25A-E0P9N104 25A-E1P7N104 25A-E3P0N104 25A-E4P2N104 25A-E6P6N104 25A-E9P9N104 25A-E012N104 25A-E019N104 25A-E022N104 25A-E027N104 25A-E032N104

0.4 0.75 1.5 2.2 4.0 5.5 7.5 11.0 15.0 18.5 22.0

ND HD HP kW HP kW

PF 525

PF 523

0.5 1.0 2.0 3.0 5.0 7.5 10.0 15.0 20.0 25.0 30.0

Output Ratings

Catalog No.(1)

Amps




31


Accessories and Dimensions Dynamic Brake Resistors Drive Ratings Input Voltage 100...120V 50/60 Hz 1-Phase

200...240V 50/60 Hz 1-Phase

200...240V 50/60 Hz 3-Phase

380...480V 50/60 Hz 3-Phase

525...600V 50/60 Hz 3-Phase

HP 0.25 0.5 1.0 1.5 0.25 0.5 1.0 2.0 3.0 0.25 0.5 1.0 2.0 3.0 5.0 7.5 10.0 15.0 20.0 0.5 1.0 2.0 3.0 5.0 7.5 10.0 15.0 20.0 25.0 30.0 0.5 1.0 2.0 3.0 5.0 7.5 10.0 15.0 20.0 25.0 30.0

kW 0.2 0.4 0.75 1.1 0.2 0.4 0.75 1.5 2.2 0.2 0.4 0.75 1.5 2.2 4.0 5.5 7.5 11.0 15.0 0.4 0.75 1.5 2.2 4.0 5.5 7.5 11.0 15.0 18.5 22.0 0.4 0.75 1.5 2.2 4.0 5.5 7.5 11.0 15.0 18.5 22.0

Minimum Resistance Ω ± 10% 56 56 56 41 56 56 56 41 32 56 56 56 41 32 18 16 14 14 10 89 89 89 89 47 47 47 43 43 27 27 112 112 112 112 86 59 59 59 59 53 34

Resistance Ω ± 5% 91 91 91 91 91 91 91 91 47 91 91 91 91 47 47 30 30 15 15 360 360 360 120 120 120 120 60 60 40 40 360 360 360 120 120 120 120 60 60 60 40

Catalog No.(1)(2) AK-R2-091P500 AK-R2-091P500 AK-R2-091P500 AK-R2-091P500 AK-R2-091P500 AK-R2-091P500 AK-R2-091P500 AK-R2-091P500 AK-R2-047P500 AK-R2-091P500 AK-R2-091P500 AK-R2-091P500 AK-R2-091P500 AK-R2-047P500 AK-R2-047P500 AK-R2-030P1K2 AK-R2-030P1K2 AK-R2-030P1K2(3) AK-R2-030P1K2(3) AK-R2-360P500 AK-R2-360P500 AK-R2-360P500 AK-R2-120P1K2 AK-R2-120P1K2 AK-R2-120P1K2 AK-R2-120P1K2 AK-R2-120P1K2(3) AK-R2-120P1K2(3) AK-R2-120P1K2(4) AK-R2-120P1K2(4) AK-R2-360P500 AK-R2-360P500 AK-R2-360P500 AK-R2-120P1K2 AK-R2-120P1K2 AK-R2-120P1K2 AK-R2-120P1K2 AK-R2-120P1K2(3) AK-R2-120P1K2(3) AK-R2-120P1K2(3) AK-R2-120P1K2(4)

(1) The resistors listed in this tables are rated for 5% duty cycle. (2) Use of Rockwell Automation resistors is always recommended. The resistors listed have been carefully selected for optimizing performance in a variety of applications. Alternative resistors may be used, however, care must be taken when making a selection. See the PowerFlex Dynamic Braking Resistor Calculator, publication PFLEX-AT001. (3) Requires two resistors wired in parallel. (4) Requires three resistors wired in parallel.

32



EMC Line Filters Short Circuit Current Rating = 100 kA Drive Ratings Input Voltage 100...120V 50/60 Hz 1-Phase

200...240V 50/60 Hz 1-Phase

200...240V 50/60 Hz 3-Phase

380...480V 50/60 Hz 3-Phase

525...600V 50/60 Hz 3-Phase

HP 0.25 0.5 1.0 1.5 0.25 0.5 1.0 2.0 3.0 0.25 0.5 1.0 2.0 3.0 5.0 7.5 10.0 15.0 20.0 0.5 1.0 2.0 3.0 5.0 7.5 10.0 15.0 20.0 25.0 30.0 0.5 1.0 2.0 3.0 5.0 7.5 10.0 15.0 20.0 25.0 30.0

kW 0.2 0.4 0.75 1.1 0.2 0.4 0.75 1.5 2.2 0.2 0.4 0.75 1.5 2.2 4.0 5.5 7.5 11.0 15.0 0.4 0.75 1.5 2.2 4.0 5.5 7.5 11.0 15.0 18.5 22.0 0.4 0.75 1.5 2.2 4.0 5.5 7.5 11.0 15.0 18.5 22.0

Current (A) 1.6 2.5 4.8 6.0 1.6 2.5 4.8 8.0 11.0 1.6 2.5 5.0 8.0 11.0 17.5 24.0 32.2 48.3 62.1 1.4 2.3 4.0 6.0 10.5 13.0 17.0 24.0 30.0 37.0 43.0 0.9 1.7 3.0 4.2 6.6 9.9 12.0 19.0 22.0 27.0 32.0

Frame Size A A B B A A A B B A A A A A B C D E E A A A A B C C D D E E A A A A B C C D D E E

Catalog No. 25-RF011-AL 25-RF011-AL 25-RF023-BL 25-RF023-BL 25-RF011-AL 25-RF011-AL 25-RF011-AL 25-RF023-BL 25-RF023-BL 25-RF014-AL 25-RF014-AL 25-RF014-AL 25-RF014-AL 25-RF014-AL 25-RF021-BL 25-RF027-CL 25-RF035-DL 25-RF056-EL 25-RF056-EL 25-RF7P5-AL 25-RF7P5-AL 25-RF7P5-AL 25-RF7P5-AL 25-RF014-BL 25-RF018-CL 25-RF018-CL 25-RF033-DL 25-RF033-DL 25-RF039-EL 25-RF039-EL(1) 25-RF8P0-BL(2) 25-RF8P0-BL(2) 25-RF8P0-BL(2) 25-RF8P0-BL(2) 25-RF8P0-BL 25-RF014-CL 25-RF014-CL 25-RF027-DL 25-RF027-DL 25-RF029-EL 25-RF029-EL(1)

(1) EMC Line Filter size is based on the input current of the drive. See the tables on page 30 and page 31 for more information. (2) This 600V drive rating needs to be matched with a frame B EMC Line Filter.


33


EMC Plates Item EMC Plate

Description Optional grounding plate for shielded cables.


Catalog No. 25-EMC1-FA 25-EMC1-FB 25-EMC1-FC 25-EMC1-FD 25-EMC1-FE

Human Interface Modules (HIM) Option Kits and Accessories Item LCD Display, Remote Panel Mount

LCD Display, Remote Handheld

Bezel Kit DSI HIM Cable (DSI HIM to RJ45 cable)

Description Digital speed control CopyCat capable IP 66 (NEMA Type 4X/12) indoor use only Includes 2.9 meter cable Digital speed control Full numeric keyboard CopyCat capable IP 30 (NEMA Type 1) Includes 1.0 m cable Panel mount with optional Bezel Kit Panel mount for LCD Display, Remote Handheld unit, IP 30 (NEMA Type 1) Includes 2.0 m DSI cable 1.0 m (3.3 ft) 2.9 m (9.51 ft)

Catalog No. 22-HIM-C2S

22-HIM-A3

22-HIM-B1 22-HIM-H10 22-HIM-H30

IP 30/NEMA 1/UL Type 1 Kit Item IP 30/NEMA 1/UL Type 1 Kit

Description Field installed kit. Converts drive to IP 30/NEMA 1/UL Type 1 enclosure. Includes conduit box with mounting screws and plastic top panel.


Catalog No. 25-JBAA 25-JBAB 25-JBAC 25-JBAD 25-JBAE

Description For use with drive in environments with ambient temperatures up to 70 °C or horizontal mounting.

Frame Size A...D E

Catalog No. 25-FAN1-70C 25-FAN2-70C

Control Module Fan Kit Item Control Module Fan Kit

Incremental Encoder Input Option Item Incremental Encoder

Description Incremental encoder input option board.

Catalog No. 25-ENC-1

WARNING: Only the 25-ENC-1 Encoder will work properly in the PowerFlex 525 drive. Installing an incorrect encoder card, such as the PowerFlex 527 25-ENC-2 will cause damage to the PowerFlex 525 drive.

34



Bulletin 160 to PowerFlex 520-Series Mounting Adapter Plate Item Mounting Adapter Plate

B160 Frame Size A B

Description For use with drive when replacing Bulletin 160 drives in existing installations to a PowerFlex 520-Series drive. Select the catalog number based on the frame size of your Bulletin 160 drive.

Catalog No. 25-MAP-FA 25-MAP-FB

Replacement Parts PowerFlex 520-Series Power Module Item PowerFlex 520-Series Power Module

Description Replacement power module for use with PowerFlex 520-Series drives. Includes: • Power Module • Power Module Front Cover • Power Terminal Guard • Heatsink Fan

Output Ratings Normal Duty Heavy Duty HP kW HP kW Output Current (A) Input Voltage Range 100...120V AC (-15%, +10%) – 1-Phase Input, 0...230V 3-Phase Output 0.25 0.2 0.25 0.2 1.6 85...132 0.5 0.4 0.5 0.4 2.5 85...132 1.0 0.75 1.0 0.75 4.8 85...132 1.5 1.1 1.5 1.1 6.0 85...132 200...240V AC (-15%, +10%) – 1-Phase Input, 0...230V 3-Phase Output 0.25 0.2 0.25 0.2 1.6 170...264 0.5 0.4 0.5 0.4 2.5 170...264 1.0 0.75 1.0 0.75 4.8 170...264 2.0 1.5 2.0 1.5 8.0 170...264 3.0 2.2 3.0 2.2 11.0 170...264 200...240V AC (-15%, +10%) – 1-Phase Input with EMC Filter, 0...230V 3-Phase Output 0.25 0.2 0.25 0.2 1.6 170...264 0.5 0.4 0.5 0.4 2.5 170...264 1.0 0.75 1.0 0.75 4.8 170...264 2.0 1.5 2.0 1.5 8.0 170...264 3.0 2.2 3.0 2.2 11.0 170...264 200...240V AC (-15%, +10%) – 3-Phase Input, 0...230V 3-Phase Output 0.25 0.2 0.25 0.2 1.6 170...264 0.5 0.4 0.5 0.4 2.5 170...264 1.0 0.75 1.0 0.75 5.0 170...264 2.0 1.5 2.0 1.5 8.0 170...264 3.0 2.2 3.0 2.2 11.0 170...264 5.0 4.0 5.0 4.0 17.5 170...264 7.5 5.5 7.5 5.5 24.0 170...264 10.0 7.5 10.0 7.5 32.2 170...264 15.0 11.0 10.0 7.5 48.3 170...264 20.0 15.0 15.0 11.0 62.1 170...264 380...480V AC (-15%, +10%) – 3-Phase Input, 0...460V 3-Phase Output 0.5 0.4 0.5 0.4 1.4 323...528 1.0 0.75 1.0 0.75 2.3 323...528


Frame Size

Catalog No.

A A B B

25-PM1-V1P6 25-PM1-V2P5 25-PM1-V4P8 25-PM1-V6P0

A A A B B

25-PM1-A1P6 25-PM1-A2P5 25-PM1-A4P8 25-PM1-A8P0 25-PM1-A011

A A A B B

25-PM2-A1P6 25-PM2-A2P5 25-PM2-A4P8 25-PM2-A8P0 25-PM2-A011

A A A A A B C D E E

25-PM1-B1P6 25-PM1-B2P5 25-PM1-B5P0 25-PM1-B8P0 25-PM1-B011 25-PM1-B017 25-PM1-B024 25-PM1-B032 25-PM1-B048 25-PM1-B062

A A

25-PM1-D1P4 25-PM1-D2P3

35


Output Ratings Normal Duty Heavy Duty HP kW HP kW Output Current (A) Input Voltage Range 2.0 1.5 2.0 1.5 4.0 323...528 3.0 2.2 3.0 2.2 6.0 323...528 5.0 4.0 5.0 4.0 10.5 323...528 7.5 5.5 7.5 5.5 13.0 323...528 10.0 7.5 10.0 7.5 17.0 323...528 15.0 11.0 15.0 11.0 24.0 323...528 20.0 15.0 15.0 11.0 30.0 323...528 380...480V AC (-15%, +10%) – 3-Phase Input with EMC Filter, 0...460V 3-Phase Output 0.5 0.4 0.5 0.4 1.4 323...528 1.0 0.75 1.0 0.75 2.3 323...528 2.0 1.5 2.0 1.5 4.0 323...528 3.0 2.2 3.0 2.2 6.0 323...528 5.0 4.0 5.0 4.0 10.5 323...528 7.5 5.5 7.5 5.5 13.0 323...528 10.0 7.5 10.0 7.5 17.0 323...528 15.0 11.0 15.0 11.0 24.0 323...528 20.0 15.0 15.0 11.0 30.0 323...528 25.0 18.5 20.0 15.0 37.0 323...528 30.0 22.0 25.0 18.5 43.0 323...528 525...600V AC (-15%, +10%) – 3-Phase Input, 0...575V 3-Phase Output 0.5 0.4 0.5 0.4 0.9 446...660 1.0 0.75 1.0 0.75 1.7 446...660 2.0 1.5 2.0 1.5 3.0 446...660 3.0 2.2 3.0 2.2 4.2 446...660 5.0 4.0 5.0 4.0 6.6 446...660 7.5 5.5 7.5 5.5 9.9 446...660 10.0 7.5 10.0 7.5 12.0 446...660 15.0 11.0 15.0 11.0 19.0 446...660 20.0 15.0 15.0 11.0 22.0 446...660 25.0 18.5 20.0 15.0 27.0 446...660 30.0 22.0 25.0 18.5 32.0 446...660

Frame Size A A B C C D D

Catalog No. 25-PM1-D4P0 25-PM1-D6P0 25-PM1-D010 25-PM1-D013 25-PM1-D017 25-PM1-D024 25-PM1-D030


25-PM2-D1P4 25-PM2-D2P3 25-PM2-D4P0 25-PM2-D6P0 25-PM2-D010 25-PM2-D013 25-PM2-D017 25-PM2-D024 25-PM2-D030 25-PM2-D037 25-PM2-D043


25-PM1-E0P9 25-PM1-E1P7 25-PM1-E3P0 25-PM1-E4P2 25-PM1-E6P6 25-PM1-E9P9 25-PM1-E012 25-PM1-E019 25-PM1-E022 25-PM1-E027 25-PM1-E032

PowerFlex 520-Series Control Module Item PowerFlex 523 Control Module PowerFlex 525 Control Module

Description Replacement control module for use with PowerFlex 520-Series drives. Includes: • Control Module • Control Module Front Cover

Frame Size A...E

Catalog No. 25A-CTM1 25B-CTM1

Description Replacement cover for the control module I/O terminals, EtherNet/IP and DSI ports.

Frame Size A...E

Catalog No. 25A-CTMFC1

Other Parts Item PowerFlex 523 Control Module Front Cover PowerFlex 525 Control Module Front Cover PowerFlex 520-Series Power Module Front Cover

36

25B-CTMFC1 Replacement cover for the PowerFlex 520-Series power module.


B C D E

25-PMFC-FB 25-PMFC-FC 25-PMFC-FD 25-PMFC-FE


Other Parts Item PowerFlex 520-Series Power Terminal Guard

Description Replacement finger guard for power terminals.

PowerFlex 520-Series Heatsink Fan Kit

Replacement fan for drive power module.

Frame Size A B C D E A B C D E

Catalog No. 25-PTG1-FA 25-PTG1-FB 25-PTG1-FC 25-PTG1-FD 25-PTG1-FE 25-FAN1-FA 25-FAN1-FB 25-FAN1-FC 25-FAN1-FD 25-FAN1-FE

Communication Option Kits and Accessories Item Communication Adapters

Description Embedded communication options for use with the PowerFlex 520-Series drives: • DeviceNet • Dual Port EtherNet/IP • PROFIBUS DP-V1 Three channel Provides serial communication via DF1 protocol for use with Connected Components Workbench software. Includes: • 2m USB cable (1) • 20-HIM-H10 cable (1) • 22-HIM-H10 cable (1) Provides serial communication via DF1 protocol for use with Connected Components Workbench software. Includes: • DSI to RS232 serial converter (1) • 1203-SFC serial cable (1) • 22-RJ45CBL-C20 cable (1) 2.0 m RJ45 to RJ45 cable, male to male connectors. 2.0 m serial cable with a locking low profile connector to connect to the serial converter and a 9-pin sub-miniature D female connector to connect to a computer. RJ45 one to two port splitter cable (Modbus only) RJ45 120 Ohm resistors (2 pieces) RJ45 Two position terminal block (5 pieces) Windows-based software packages for programming and configuring Allen-Bradley drives and other Rockwell Automation products. Compatibility: Windows XP, Windows Vista and Windows 7

Compact I/O Module Universal Serial Bus™ (USB) Converter Module

Serial Converter Module (RS485 to RS232)

DSI Cable Serial Cable Splitter Cable Terminating Resistors Terminal Block Connected Components Workbench Software (Download or DVD-ROM)

Catalog No. 25-COMM-D 25-COMM-E2P 25-COMM-P 1769-SM2 1203-USB

22-SCM-232

22-RJ45CBL-C20 1203-SFC AK-U0-RJ45-SC1 AK-U0-RJ45-TR1 AK-U0-RJ45-TB2P http://ab.rockwellautomation.com/ programmable-controllers/connectedcomponents-workbench-software

Bulletin 1321-3R Series Line Reactors Output Ratings(1)

Input Line Reactor(3)(4)

Normal Duty

Heavy Duty

HP

HP

kW

Output Line Reactor(3)(4)

IP 00 (Open Style)

IP 11 (NEMA/UL Type 1)

IP 00 (Open Style)


kW

Catalog No.

Catalog No.

Catalog No.

Catalog No.

200...240V 50/60 Hz 1-Phase(2) 0.25

0.2

0.25

0.2

1321-3R4-A

1321-3RA4-A

1321-3R2-D

1321-3RA2-D

0.5

0.4

0.5

0.4

1321-3R8-A

1321-3RA8-A

1321-3R2-D

1321-3RA2-D

1.0

0.75

1.0

0.75

1321-3R8-A

1321-3RA8-A

1321-3R4-A

1321-3RA4-A

2.0

1.5

2.0

1.5

1321-3R18-A

1321-3RA18-A

1321-3R8-A

1321-3RA8-A

3.0

2.2

3.0

2.2

1321-3R18-A

1321-3RA18-A

1321-3R12-A

1321-3RA12-A

200...240V 50/60 Hz 3-Phase


37


Bulletin 1321-3R Series Line Reactors Output Ratings(1)

Input Line Reactor(3)(4)

Output Line Reactor(3)(4)

Normal Duty

Heavy Duty

IP 00 (Open Style)


IP 00 (Open Style)


HP

kW

HP

0.25

0.2

0.25

kW

Catalog No.

Catalog No.

Catalog No.

Catalog No.

0.2

1321-3R2-D

1321-3RA2-D

1321-3R2-D

1321-3RA2-D

0.5

0.4

0.5

0.4

1321-3R2-D

1.0

0.75

1.0

0.75

1321-3R4-A

1321-3RA2-D

1321-3R2-D

1321-3RA2-D

1321-3RA4-A

1321-3R4-A

1321-3RA4-A

2.0

1.5

2.0

1.5

1321-3R8-A

1321-3RA8-A

1321-3R8-A

1321-3RA8-A

3.0

2.2

3.0

2.2

5.0

4.0

5.0

4.0

1321-3R12-A

1321-3RA12-A

1321-3R12-A

1321-3RA12-A

1321-3R18-A

1321-3RA18-A

1321-3R18-A

7.5

5.5

7.5

5.5

1321-3RA18-A

1321-3R25-A

1321-3RA25-A

1321-3R25-A

1321-3RA25-A

10.0

7.5

10.0

7.5

1321-3R35-A

1321-3RA35-A

1321-3R35-A

1321-3RA35-A

15.0

11.0

10.0

7.5

1321-3R45-A

1321-3RA45-A

1321-3R45-A

1321-3RA45-A

20.0

15.0

15.0

11.0

1321-3R55-A (ND) 1321-3R45-A (HD)

1321-3RA55-A (ND) 1321-3RA45-A (HD)

1321-3R55-A (ND) 1321-3R45-A (HD)

1321-3RA55-A (ND) 1321-3RA45-A (HD)

380...480V 50/60 Hz 3-Phase 0.5

0.4

0.5

0.4

1321-3R2-B

1321-3RA2-B

1321-3R2-B

1321-3RA2-B

1.0

0.75

1.0

0.75

1321-3R4-C

1321-3RA4-C

1321-3R4-C

1321-3RA4-C

2.0

1.5

2.0

1.5

1321-3R4-B

1321-3RA4-B

1321-3R4-B

1321-3RA4-B

3.0

2.2

3.0

2.2

1321-3R8-C

1321-3RA8-C

1321-3R8-C

1321-3RA8-C

5.0

4.0

5.0

4.0

1321-3R12-B

1321-3RA12-B

1321-3R12-B

1321-3RA12-B

7.5

5.5

7.5

5.5

1321-3R12-B

1321-3RA12-B

1321-3R12-B

1321-3RA12-B

10.0

7.5

10.0

7.5

1321-3R18-B

1321-3RA18-B

1321-3R18-B

1321-3RA18-B

15.0

11.0

15.0

11.0

1321-3R25-B

1321-3RA25-B

1321-3R25-B

1321-3RA25-B

20.0

15.0

15.0

11.0

1321-3R35-B (ND) 1321-3R25-B (HD)

1321-3RA35-B (ND) 1321-3RA25-B (HD)

1321-3R35-B (ND) 1321-3R25-B (HD)

1321-3RA35-B (ND) 1321-3RA25-B (HD)

25.0

18.5

20.0

15.0

1321-3R35-B

1321-3RA35-B

1321-3R35-B

1321-3RA35-B

30.0

22.0

25.0

18.5

1321-3R45-B (ND) 1321-3R35-B (HD)

1321-3RA45-B (ND) 1321-3RA35-B (HD)

1321-3R45-B (ND) 1321-3R35-B (HD)

1321-3RA45-B (ND) 1321-3RA35-B (HD)

525...600V 50/60 Hz 3-Phase 0.5

0.4

0.5

0.4

1321-3R1-C

1321-3RA1-C

1321-3R1-C

1321-3RA1-C

1.0

0.75

1.0

0.75

1321-3R2-B

1321-3RA2-B

1321-3R2-B

1321-3RA2-B

2.0

1.5

2.0

1.5

1321-3R4-C

1321-3RA4-C

1321-3R4-C

1321-3RA4-C

3.0

2.2

3.0

2.2

1321-3R4-B

1321-3RA4-B

1321-3R4-B

1321-3RA4-B

5.0

4.0

5.0

4.0

1321-3R8-C

1321-3RA8-C

1321-3R8-C

1321-3RA8-C

7.5

5.5

7.5

5.5

1321-3R12-B

1321-3RA12-B

1321-3R12-B

1321-3RA12-B

10.0

7.5

10.0

7.5

1321-3R12-B

1321-3RA12-B

1321-3R12-B

1321-3RA12-B

15.0

11.0

15.0

11.0

1321-3R18-B

1321-3RA18-B

1321-3R18-B

1321-3RA18-B

20.0

15.0

15.0

11.0

1321-3R25-B (ND) 1321-3R18-B (HD)

1321-3RA25-B (ND) 1321-3RA18-B (HD)

1321-3R25-B (ND) 1321-3R18-B (HD)

1321-3RA25-B (ND) 1321-3RA18-B (HD)

25.0

18.5

20.0

15.0

1321-3R35-C (ND) 1321-3R25-C (HD)

1321-3RA35-C (ND) 1321-3RA25-C (HD)

1321-3R35-C (ND) 1321-3R25-C (HD)

1321-3RA35-C (ND) 1321-3RA25-C (HD)

30.0

22.0

25.0

18.5

1321-3R35-C (ND) 1321-3R25-B (HD)

1321-3RA35-C (ND) 1321-3RA25-B (HD)

1321-3R35-C (ND) 1321-3R25-B (HD)

1321-3RA35-C (ND) 1321-3RA25-B (HD)

(1) (2) (3) (4)

38

Normal Duty and Heavy Duty ratings for 15 HP (11 kW) and below are identical except for 200...240V 3-Phase 15 HP (11 kW) drive. Standard 3-phase reactors can be used for 1-phase applications by routing each of the two supply conductors through an outside coil and leaving the center open. Catalog numbers listed are for 3% impedance. 5% impedance reactor types are also available. See 1321 Power Conditioning Products Technical Data, publication 1321-TD001. Input line reactors were sized based on the NEC fundamental motor amps. Output line reactors were sized based on the VFD rated output currents.



Accessory Dimensions IP 30/NEMA 1/UL Type 1 Kit – Dimensions are in mm and (in.). Frame A

15.0 (0.59)

D

A

51.1 (2.01) 21.0 (0.82) ø21.5 (ø0.85)

64.7 (2.55) 88.2 (3.47) 111.9 (4.41) 135.4 (5.33)

B

Sel

E H

96.0 (3.78) 70.0 (2.76)

44.0 (1.73) 30.0 (1.18) ø21.5 (ø0.85) ø33.5 (ø1.32) 153.3 (6.04)

Esc

Frame D

Frame B 33.5 (1.32) 23.9 (0.94)

109.8 (4.32)

66.1 (2.60) 63.1 (2.48)

67.3 (2.65) 88.3 (3.48) 108.5 (4.27) 128.5 (5.06)

ø21.5 (ø0.85) ø27.5 (ø1.08)

C

Frame E 127.5 (5.02) 82.5 (3.25)

62.5 (2.46) 42.5 (1.67) ø21.5 (ø0.85) ø43.7 (ø1.72)

80.5 (3.17) 66.5 (2.62)

164.0 (6.46) 181.0 (7.13) 212.0 (8.35)

Frame C 34.5 (1.36) 26.5 (1.04) ø21.5 (ø0.85) ø27.5 (ø1.08)

82.2 (3.24) 123.3 (4.85)

F

G


A 72.0 (2.83) 87.0 (3.43) 109.0 (4.29) 130.0 (5.12) 185.0 (7.28)

B 219.0 (8.62) 218.0 (8.58) 255.0 (10.04) 295.0 (11.61) 350.0 (13.78)

C 172.0 (6.77) 172.0 (6.77) 184.0 (7.24) 212.0 (8.35) 279.0 (10.98)

D 57.5 (2.26) 72.5 (2.85) 90.5 (3.56) 116.0 (4.57) 160.0 (6.30)

E 152.0 (5.98) 180.0 (7.09) 222.0 (8.66) 260.0 (10.24) 300.0 (11.81)


F 92.7 (3.65) 92.7 (3.65) 92.7 (3.65) – –

G 6.0 (0.24) 6.0 (0.24) 6.0 (0.24) 6.0 (0.24) 7.6 (0.30)

H 140.0 (5.51) 168.0 (6.61) 207.0 (8.15) 247.0 (9.74) 280.0 (11.02)

39


Control Module Fan Kit – Dimensions are in mm and (in.). A C E

E

A 52.0 (2.05)

A C

Frame E 32.0 (1.26)

Frame A...D

F

F

Esc

Sel

Esc

Sel

B

B D

D


A 72.0 (2.83) 87.0 (3.43) 109.0 (4.29) 130.0 (5.12) 196.0 (7.72)

Specifications Rated Voltage Operation Voltage Input Current Speed (Reference) Maximum Air Flow (At zero static pressure) Maximum Air Pressure (At zero air flow) Acoustical Noise Insulation Type Frame Size Wire Size Torque

40

B 152.0 (5.98) 180.0 (7.09) 220.0 (8.66) 260.0 (10.24) 300.0 (11.81)

C 57.5 (2.26) 72.5 (2.85) 90.5 (3.56) 116.0 (4.57) 185.0 (7.28)

D 140.0 (5.51) 168.0 (6.61) 207.0 (8.15) 247.0 (9.72) 280.0 (11.02)

25-FAN1-70C 24V DC 14...27.6V DC 0.1 A 7000 rpm 0.575 m3/min 7.70 mmH2O 40.5 dB-A UL Class A Frame A...D 0.32 mm2 (22 AWG) 0.29...0.39 Nm (2.6...3.47 lb-in.)


E 56.0 (2.20) 56.0 (2.20) 56.0 (2.20) 56.0 (2.20) 196.0 (7.72) 25-FAN2-70C

0.15 A 4500 ± 10% rpm 1.574 m3/min 9.598 mmH2O 46.0 dB-A Frame E

F 99.8 (3.93) 99.8 (3.93) 99.8 (3.93) 99.8 (3.93) 114.3 (4.50)


EMC Line Filter – Dimensions are in mm and (in.). Frame A...D D

Frame E

A

ø5.5 (ø0.22)

B F

E

C

D

A

B F

H

E E

L1 L2 L3 BLACK BLACK BLACK

G

ø5.5 (ø0.22)

H

YELLOW & GREEN

C

E

I

F G

I

H F


A 55.0 (2.17) 70.0 (2.76) 70.0 (2.76) 80.0 (3.15) 80.0 (3.15)

B 72.0 (2.83) 87.0 (3.43) 109.0 (4.29) 130.0 (5.12) 155.0 (6.10)

C 234.0 (9.21) 270.0 (10.63) 275.0 (10.83) 310.0 (12.20) 390.0 (15.35)

D 30.0 (1.18) 35.0 (1.38) 37.0 (1.46) 33.0 (1.30) 33.0 (1.30)

E 223.0 (8.78) 258.0 (10.16) 263.0 (10.35) 298.0 (11.73) 375.0 (14.76)

F 54.0 (2.13) 58.0 (2.28) 76.0 (2.99) 90.0 (3.54) 110.0 (4.33)


G 20.0 (0.79) 25.0 (0.98) 25.0 (0.98) 33.0 (1.30) 33.0 (1.30)

H 23.0 (0.91) 24.0 (0.94) 28.0 (1.10) 28.0 (1.10) 28.0 (1.10)

I 5.5 (0.22) 5.5 (0.22) 5.5 (0.22) 5.5 (0.22) 5.5 (0.22)

41


Safe-Torque-Off Function The PowerFlex 525 Safe-Torque-Off function, when used with other safety components, helps provide protection according to EN ISO 13849 and EN62061 for safe-off and protection against restart. The PowerFlex 525 Safe-Torque-Off function is just one component in a safety control system. Components in the system must be chosen and applied appropriately to achieve the desired level of operator safeguarding.

PowerFlex 525 Safe-Torque-Off Overview The PowerFlex 525 Safe-Torque-Off function: • Provides the Safe-Torque-Off (STO) function defined in EN IEC 61800-5-2. • Blocks gate-firing signals from reaching the Insulated Gate Bipolar Transistor (IGBT) output devices of the drive. This prevents the IGBTs from switching in the sequence necessary to generate torque in the motor. • Can be used in combination with other safety devices to fulfill the requirements of a system “safe torque off ” function which satisfies Category 3 / PL (d) according to EN ISO 13849-1 and SIL CL2 according to EN 62061, IEC 61508, and EN 61800-5-2. IMPORTANT

The function is suitable for performing mechanical work on the drive system or affected area of a machine only. It does not provide electrical safety.

EC Type Examination Certification TÜV Rheinland has certified the PowerFlex 525 Safe-Torque-Off function compliant with the requirements for machines defined in Annex I of the EC Directive 2006/42/EC, and that it complies with the requirements of the relevant standards listed below: • EN ISO 13849-1 Safety of machinery – Safety related parts of control systems – Part 1: General principles for design. (PowerFlex 525 STO achieves Category 3 / PL(d)) • EN 61800-5-2 Adjustable speed electrical power drive systems – Part 5-2 Safety requirements – Functional. (PowerFlex 525 STO achieves SIL CL 2) • EN 62061 Safety of machinery – Functional safety of safety-related electrical, electronic and programmable electronic control systems. • IEC 61508 Part 1-7 Functional safety of electrical/electronic/programmable electronic safety-related systems – Parts 1-7. TÜV also certifies that the PowerFlex 525 STO may be used in applications up to Category 3/ PL(d) according to EN ISO 13849-1 and SIL 2 according to EN 62061 / EN 61800-5-2 / IEC 61508. The TÜV Rheinland certificate may be found at http://www.rockwellautomation.com/products/certification/.

42



Safety Concept The PowerFlex 525 Safe-Torque-Off function is suitable for use in safety applications up to and including Category 3 / PL(d) according to EN ISO 13849-1 and SIL 2 according to EN 62061 / EN 61800-5-2 / IEC 61508. In addition, the PowerFlex 525 STO function may be used together with other components in a safety application to achieve an overall Category 3 / PL(e) according to EN ISO 13849-1 and SIL 3 according to EN 62061 and IEC 61508. This is illustrated in Example 3 on page 46. Safety requirements are based on the standards current at the time of certification. The PowerFlex 525 STO function is intended for use in safety-related applications where the de-energized state is considered to be the safe state. All of the examples shown here are based on achieving de-energization as the safe state for typical Machine Safety and Emergency Shutdown (ESD) systems.

PFD and PFH Data PFD and PFH calculations are based on the equations from Part 6 of EN 61508. This table provides data for a 20-year proof test interval and demonstrates the worst-case effect of various configuration changes on the data. PFD and PFH for 20-year Proof Test Interval Attribute PFD PFHD SFF DC CAT HFT PTI Hardware Type

Value 6.62E-05 (MTTF = 3593 years) 8.13E-10 83% 62.5% 3 1 (1oo2) 20 YEARS Type A

Safety Reaction Time The safety reaction time from an input signal condition that triggers a safe stop, to the initiation of the configured Stop Type, is 100 ms (maximum).


43


Connection Examples Example 1 – Safe-Torque-Off Connection with Coast-to-Stop Action, SIL 2/PL d Stop Category 0 – Coast AC line input power PF 525

+24V DC

+24V DC

GuardMaster Trojan

Gate

Stop Stop

Start

Start

A1 S21 S11 S52 41 13 23 33

Gate control power supply

MSR

E-Stop latching button

A2 S22 S14 S34 42 14 24 34 24V DC common

Gate control circuit S1 S2

(1)

M

AC line input power PF 525 +24V DC

GuardMaster Trojan

Gate

Stop Stop Start

E-Stop latching button

Start


Gate control circuit S1 S2 (2)

M (1) Enclosure Recommended. Note: External wiring failure modes must be considered as described in EN ISO 13849-2. Enclosure or other measure to exclude these failure modes should be used. (2) In some situations, a safety relay is not required if both the switch and PowerFlex 525 are installed in the same enclosure.

44



Stop Category 0 – Coast with Two PowerFlex 525 Drives 24V DC Supply

(1)

AC line input power

Reset PF 525 E-Stop

AC line input power

+24V DC A1 S11

L12

SI

S21

Start

PF 525

Start

+24V DC

Dig. comm Y32

S12 S22

Stop

Stop

L11

Reset 0

S34

Stop

Stop


Start

Start Dig. comm

AM MM


Gate control circuit

13

(2)

14 23

S1

Gate control circuit

S2

(2)

24 A2

S1 S2

M

M 24V DC COM

(1) Enclosure Recommended. Note: External wiring failure modes must be considered as described in EN ISO 13849-2. Enclosure or other measure to exclude these failure modes should be used. (2) Each safety input draws 6 mA from the supply.

Example 2 – Safe-Torque-Off Connection with Controlled Stop Action, SIL 2/PL d Stop Category 1– Controlled (1)

AC line input power PF 525

GuardMaster Trojan

+24V DC

Gate

A1

Start S21 S11 S52 S12 S22

37 47 57

13 23

Start

S33 S34


Minotaur MSR138DP A2 X1 X2 X3 X4 Y39 Y40 38 48 58

24V DC Common

Stop

Stop

+24V DC

14 24

Y2 Y1

Gate control circuit S1 S2

M

(1) Enclosure Recommended. Note: External wiring failure modes must be considered as described in EN ISO 13849-2. Enclosure or other measure to exclude these failure modes should be used.


45


Example 3 – Safe-Torque-Off Connection with Coast-to-Stop Action Using External +24V supply, SIL 3/PL e Stop Category 0 – Coast (1)

AC line input power PF 525 External +24V DC

+24V DC Stop Reset

Open

A1 S11 S52 S12 13 23 33 41

Start COM Gate control power supply

MSR127TP S21 S22 S34 A2 14 24 34 42

Closed Gate control circuit S1 S2

X1 AUX X2 A1 Coil A2 24V DC COM

13 23 33 14 24 34

External 100-C contactor 100S-C

M (1) Enclosure Recommended. Note: External wiring failure modes must be considered as described in EN ISO 13849-2. Enclosure or other measure to exclude these failure modes should be used.

46



Additional Resources These documents contain additional information concerning related products from Rockwell Automation. Title PowerFlex 520-Series Adjustable Frequency AC Drive User Manual PowerFlex 4-Class Human Interface Module (HIM) DSI Quick Reference PowerFlex 525 Embedded EtherNet/IP Adapter User Manual PowerFlex 25-COMM-D DeviceNet Adapter User Manual PowerFlex 25-COMM-E2P EtherNet/IP Adapter User Manual PowerFlex 25-COMM-P PROFIBUS DP Adapter User Manual Dynamic Braking Resistor Calculator Wiring and Grounding Guidelines for PWM AC Drives Preventive Maintenance of Industrial Control and Drive System Equipment Safety Guidelines for the Application, Installation and Maintenance of Solid State Control

Publication 520-UM001 22HIM-QR001 520COM-UM001 520COM-UM002 520COM-UM003 520COM-UM004 PFLEX-AT001 DRIVES-IN001 DRIVES-TD001 SGI-1.1

You can view or download publications at http://www.rockwellautomation.com/literature/. To order paper copies of technical documentation, contact your local Allen-Bradley distributor or Rockwell Automation sales representative.


47

Important Information Solid-state equipment has operational characteristics differing from those of electromechanical equipment. Safety Guidelines for the Application, Installation and Maintenance of Solid State Controls (publication SGI-1.1 available from your local Rockwell Automation sales office or online at http://www.rockwellautomation.com/literature/) describes some important differences between solid-state equipment and hard-wired electromechanical devices. Because of this difference, and also because of the wide variety of uses for solid-state equipment, all persons responsible for applying this equipment must satisfy themselves that each intended application of this equipment is acceptable. In no event will Rockwell Automation, Inc. be responsible or liable for indirect or consequential damages resulting from the use or application of this equipment. The examples and diagrams in this publication are included solely for illustrative purposes. Because of the many variables and requirements associated with any particular installation, Rockwell Automation, Inc. cannot assume responsibility or liability for actual use based on the examples and diagrams. No patent liability is assumed by Rockwell Automation, Inc. with respect to use of information, circuits, equipment, or software described in this manual. Reproduction of the contents of this manual, in whole or in part, without written permission of Rockwell Automation, Inc., is prohibited.

Documentation Feedback Your comments will help us serve your documentation needs better. If you have any suggestions on how to improve this document, complete this form, publication RA-DU002, available at http://www.rockwellautomation.com/literature/.

Allen-Bradley, Rockwell Software, Rockwell Automation, PowerFlex, Connected Components Workbench, Studio 5000, DriveTools SP, AppView, CustomView, QuickView, MainsFree Programming, and PointStop are trademarks of Rockwell Automation, Inc. Trademarks not belonging to Rockwell Automation are property of their respective companies.

www.rockwel lautomation.com Power, Control and Information Solutions Headquarters Americas: Rockwell Automation, 1201 South Second Street, Milwaukee, WI 53204-2496 USA, Tel: (1) 414.382.2000, Fax: (1) 414.382.4444 Europe/Middle East/Africa: Rockwell Automation NV, Pegasus Park, De Kleetlaan 12a, 1831 Diegem, Belgium, Tel: (32) 2 663 0600, Fax: (32) 2 663 0640 Asia Pacific: Rockwell Automation, Level 14, Core F, Cyberport 3, 100 Cyberport Road, Hong Kong, Tel: (852) 2887 4788, Fax: (852) 2508 1846

Publication 520-TD001E-EN-E - July 2016 Supersedes Publication 520-TD001D-EN-E – January 2014

Copyright © 2016 Rockwell Automation, Inc. All rights reserved.

520-TD001E-EN-E PowerFlex 520-Series AC Drive

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